Corrosion-resistant coated copper and method for making the same

ABSTRACT

A corrosion-resistant coated base metal coated with a corrosion resistant alloy. The corrosion resistant alloy includes tin and zinc. The corrosion resistant coated base metal includes a heat created intermetallic layer primarily including copper and zinc.

This patent application is a continuation-in-part of co-pending Ser. No.10/144,128 filed May 10, 2002, now abandoned, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, now abandoned,which in turn is a continuation-in-part of Ser. No. 08/929,623 filedSep. 15, 1997, now abandoned, which in turn is a continuation-in-part ofSer. No. 08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849,which in turn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995,now U.S. Pat. No. 5,616,424, which in turn is a divisional of Ser. No.08/402,925 filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which inturn is a continuation-in-part of Ser. No. 08/165,085 filed Dec. 10,1993, now U.S. Pat. No. 5,397,652, which in turn is acontinuation-in-part of Ser. No. 08/000,101 filed Jan. 4, 1993, nowabandoned, which in turn is a continuation-in-part of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

This patent application is also a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/260,333 filed Jun. 15, 1994, nowU.S. Pat. No. 5,429,882, which in turn is a continuation-in-part of Ser.No. 08/209,400 filed Mar. 14, 1994, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993, nowU.S. Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is acontinuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now abandoned.

This patent application is further a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/341,365 filed Nov. 17, 1994, nowU.S. Pat. No. 5,489,490, which in turn is a continuation-in-part of Ser.No. 08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, whichin turn is a continuation-in-part of Ser. No. 08/154,376 filed Nov. 17,1993, now abandoned, which in turn is a continuation of Ser. No.08/042,649 filed Apr. 5, 1993, now abandoned.

This patent application is still further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/347,261 filed Nov. 30, 1994, nowU.S. Pat. No. 5,491,035, which in turn is a continuation-in-part of Ser.No. 08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, whichin turn is a continuation-in-part of Ser. No. 08/154,376 filed Nov. 17,1993, now abandoned, which in turn is a continuation of Ser. No.08/042,649 filed Apr. 5, 1993, now abandoned.

This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/175,523 filed Dec. 30, 1993, nowU.S. Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is acontinuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now abandoned.

This patent application is also a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/373,533 filed Jan. 17, 1995, nowU.S. Pat. No. 5,455,122, which in turn is a continuation of Ser. No.08/254,875 filed Jun. 6, 1994, now abandoned, which in turn is adivisional of Ser. No. 08/209,400 filed Mar. 14, 1994, now abandoned,which in turn is a continuation-in-part of Ser. No. 08/175,523 filedDec. 30, 1993, now U.S. Pat. No. 5,401,586, which in turn is acontinuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993, nowabandoned, which in turn is a continuation of Ser. No. 08/042,649 filedApr. 5, 1993, now abandoned.

This patent application is further a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,074 filed Feb. 20, 1996, now U.S. Pat. No. 5,667,849, which inturn is a divisional of Ser. No. 08/551,456 filed Nov. 1, 1995, now U.S.Pat. No. 5,616,424, which in turn is a divisional of Ser. No. 08/402,925filed Mar. 13, 1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/338,337 filed Nov. 14, 1994, nowabandoned, which in turn is a divisional of 08/229,097 filed Apr. 18,1994, now U.S. Pat. No. 5,395,702, which in turn is a continuation ofSer. No. 08/000,101 filed Jan. 4, 1993, now abandoned, which in turn isa continuation-in-part of Ser. No. 07/858,662 filed Mar. 27, 1992, nowU.S. Pat. No. 5,314,758.

This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 1995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/338,386 filed Nov. 14, 1994, now U.S. Pat. No. 5,470,667, which inturn is a continuation of Ser. No. 08/175,523 filed Dec. 30, 1993, nowU.S. Pat. No. 5,401,586, which in turn is a continuation-in-part of Ser.No. 08/154,376 filed Nov. 17, 1993, now abandoned, which in turn is acontinuation of Ser. No. 08/042,649 filed Apr. 5, 1993, now abandoned.

This patent application is also a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 1995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/260,333 filed Jun. 15, 1994, now U.S. Pat. No. 5,429,882, which inturn is a continuation-in-part of Ser. No. 08/209,400 filed Mar. 14,1994, now abandoned, which in turn is a continuation-in-part of Ser. No.08/175,523 filed Dec. 30, 1993, now U.S. Pat. No. 5,401,586, which inturn is a continuation-in-part of Ser. No. 08/154,376 filed Nov. 17,1993, now abandoned, which in turn is a continuation of Ser. No.08/042,649 filed Apr. 5, 1993, now abandoned.

This patent application is further a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 1995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/341,365 filed Nov. 17, 1994, now U.S. Pat. No. 5,489,490, which inturn is a continuation-in-part of Ser. No. 08/175,523 filed Dec. 30,1993, now U.S. Pat. No. 5,401,586, which in turn is acontinuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993, nowabandoned, which in turn is a continuation of Ser. No. 08/042,649 filedApr. 5, 1993, now abandoned.

This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 08/929,623 filed Sep. 15, 1997, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/604,078 filed Feb. 20, 1996, now U.S. Pat. No. 5,695,822, which inturn is a divisional of Ser. No. 08/438,042 filed May 8, 995, now U.S.Pat. No. 5,597,656, which in turn is a continuation-in-part of Ser. No.08/347,261 filed Nov. 30, 1994, now U.S. Pat. No. 5,491,035, which inturn is a continuation-in-part of Ser. No. 08/175,523 filed Dec. 30,1993, now U.S. Pat. No. 5,401,586, which in turn is acontinuation-in-part of Ser. No. 08/154,376 filed Nov. 17, 1993, nowabandoned, which in turn is a continuation of Ser. No. 08/042,649 filedApr. 5, 1993, now abandoned.

This patent application is further a continuation-in-part of co-pendingSer. No 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 08/980,985 filed Oct. 20, 1997, nowabandoned, which in turn is a continuation of Ser. No. 08/636,179 filedApr. 22, 1996, now abandoned, which in turn is a continuation-in-part ofSer. No. 08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424,which in turn is a divisional of Ser. No. 08/402,925 filed Mar. 13,1995, now U.S. Pat. No. 5,491,036, which in turn is acontinuation-in-part of Ser. No. 08/380,372 filed Jan. 30, 1995, nowU.S. Pat. No. 5,480,731, which is in turn a continuation of Ser. No.08/153,026 filed Nov. 17, 1993, now U.S. Pat. No. 5,395,703, which inturn is a divisional of Ser. No. 07/858,662 filed Mar. 27, 1992, nowU.S. Pat. No. 5,314,758.

This patent application is still further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/071,316 filed May 1, 1998, nowU.S. Pat. No. 6,080,497, which in turn is a continuation-in-part of Ser.No. 08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/165,085 filed Dec. 10, 1993, now U.S. Pat. No. 5,397,652, whichin turn is a continuation-in-part of Ser. No. 08/000,101 filed Jan. 4,1993, now abandoned, which in turn is a continuation-in-part of Ser. No.07/967,407 filed Oct. 26, 1992, now abandoned, which in turn is acontinuation-in-part of Ser. No. 07/913,209 filed Jul. 15, 1992, nowabandoned, which in turn is a continuation-in-part of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/100,578 filed Jun. 19, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

This patent application is also a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 09/131,219 filed Aug. 7, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

This patent application is further a continuation-in-part of co-pendingSer. No. 10/144,128 filed May 10, 2002, which in turn is a continuationof Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn is acontinuation-in-part of Ser. No. 09/161,573 filed Sep. 28, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

This patent application is still further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/161,580 filed Sep. 28, 1998, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

This patent application is yet further a continuation-in-part ofco-pending Ser. No. 10/144,128 filed May 10, 2002, which in turn is acontinuation of Ser. No. 09/634,828 filed Aug. 9, 2000, which in turn isa continuation-in-part of Ser. No. 09/420,165 filed Oct. 18, 1999, nowabandoned, which in turn is a continuation-in-part of Ser. No.08/929,623 filed Sep. 15, 1997, now abandoned, which in turn is acontinuation-in-part of Ser. No. 08/604,074 filed Feb. 20, 1996, nowU.S. Pat. No. 5,667,849, which in turn is a divisional of Ser. No.08/551,456 filed Nov. 1, 1995, now U.S. Pat. No. 5,616,424, which inturn is a divisional of Ser. No. 08/402,925 filed Mar. 13, 1995, nowU.S. Pat. No. 5,491,036, which in turn is a continuation-in-part of Ser.No. 08/380,372 filed Jan. 30, 1995, now U.S. Pat. No. 5,480,731, whichis in turn a continuation of Ser. No. 08/153,026 filed Nov. 17, 1993,now U.S. Pat. No. 5,395,703, which in turn is a divisional of Ser. No.07/858,662 filed Mar. 27, 1992, now U.S. Pat. No. 5,314,758.

The present invention relates to the art of a corrosion-resistant metalmaterial and more particularly to a coated copper metal which is coatedwith a corrosion resistant tin and zinc alloy.

INCORPORATION BY REFERENCE

As background material so that the specification need not specify indetail what is known in the art, U.S. Pat. Nos. 4,934,120; 4,982,543;4,987,716; 4,934,120; 5,001,881; 5,022,203; 5,259,166; and 5,301,474 areincorporated herein by reference to illustrate metal roofing systems ofthe type to which this invention can be used. U.S. Pat. No. 5,455,122 isincorporated herein by reference to illustrate petroleum receptacles ofthe type to which this invention can be used. U.S. Pat. Nos. 5,296,300;5,314,758; 5,354,624; 5,395,702; 5,395,703; 5,397,652; 5,401,586;5,429,882; 5,455,122; 5,470,667; 5,480,731; 5,489,490; 5,491,035;5,491,036; 5,492,772; 5,520,964; 5,597,656; 5,616,424; 5,667,849,5,695,822; and 6,080,497 and U.S. patent application Ser. No.07/913,209, filed Jul. 15, 1992; Ser. No. 08/042,649, filed Apr. 5,1993; Ser. No. 08/929,623, filed Sep. 15, 1997; Ser. No. 08/980,985,filed Oct. 20, 1997; Ser. No. 09/100,578, filed Jun. 19, 1998; Ser. No.09/131,219, filed Aug. 7, 1998; Ser. No. 09/161,573, filed Sep. 28,1998; Ser. No. 09/161,580, filed Sep. 28, 1998; Ser. No. 09/420,165,filed Oct. 18, 1999; and Ser. No. 09/634,828 filed Aug. 9, 2000 areincorporated herein by reference to illustrate various coatings andprocesses that can be used to coat, treat and use the coated base metal.

BACKGROUND OF THE INVENTION

The present invention relates to the art of a base metal which is coatedwith a corrosion resistant metal alloy, which corrosion-resistant metalmaterial can be used in a wide variety of applications such as, but notlimited to, architectural or building materials such as roofingmaterials, siding materials, window frames, sheet metal, metal platesand the like; truck and automotive products such as, but not limited to,gasoline tanks, filter casings, body molding, body parts and the like;household products such as, but not limited to, appliance housings,electrical housings, light fixtures and the like; marine products suchas, but not limited to, boat hulls, boat masts, dock system components,water retaining systems; and/or other types of metal materials such as,but not limited to, tools, machinery, wires, cables, electrodes, solderand the like. The invention also relates to several novel methods andprocesses for forming base metals coated with the metal alloy materials,such as but not limited to, coated metal forming by a hot-dip process(i.e plating of metal alloy and subsequent flow heating, immersion inmolten metal alloy, metal spraying of metal alloy, and/or roller coatingof metal alloy), pretreatment of the base metal prior to metal alloycoating, applying an intermediate barrier metal layer prior to metalalloy coating, post-treating the metal alloy or coated base metal,and/or forming the metal alloy or coated base metal into a variety ofdifferent articles.

Over the last several years, there has been a trend in the industry toproduce products which are higher in quality, are environmentallyfriendly, and are safe for use by humans, animals, and/or plants. Thispush for quality, safety and environmental friendliness is very apparentin the automotive industry wherein both consumer groups andenvironmental organizations are constantly lobbying for safer,higher-quality vehicles that are more fuel efficient and lessdetrimental to the environment. Recycling old vehicles has been oneanswer to resolving the environmental issues associated with vehicleswhich have run out their useful life. Automotive salvage markets havedeveloped for these vehicles. The vehicles are partially dismantled andsold as scrap metal wherein the metal is melted down and reformed intovarious parts. Because of the environmentally-un-friendly nature oflead, the gasoline tanks of vehicles must be removed prior to therecycling of the vehicle. Gasoline tanks are commonly made of carbon orstainless steel that are coated with a terne alloy.

Other industries have also demanded higher quality products. Theseindustries include the building industry and marine industry.Corrosion-resistant products that are exposed to various corrosiveenvironments are constantly in demand. Historically, terne coatedproducts were used to coat carbon steel sheets and other carbon steelarticles to effectively and inexpensively provide corrosion-resistanceto the carbon steel in various applications. Terne or terne alloy is aterm commonly used to describe a metal alloy containing about 80% leadand the balance tin. The terne alloy is commonly applied to a the carbonsteel by immersing the carbon steel in a molten bath of terne metal by acontinuous or batch process.

Although terne coated metals have excellent corrosion-resistantproperties and have been used in various applications, terne coatedmaterials have been questioned due to environmental concerns based onthe high lead content of the alloy. Environmental and public safety lawshave been proposed and/or passed prohibiting or penalizing the user ofmaterials containing a significant portion of lead. As a result, theseterne coated articles are typically disposed of in dumping yards orlandfills. Not only do these the terne coated articles take up space inthe landfills, but there is a concern with the lead leaching from theterne coating into the landfill site and potentially contaminating thesurrounding area and underground water reservoirs.

The lead content in terne coated materials is also of some concern forbuilding materials and marine applications. This is especially a concernwhen the terne coated materials are in contact with drinking water. Inmany countries, lead pipe has been outlawed to reduce the amount of leadin the water. In many remote locations throughout the world, piped wateror well water is not readily available. As a result, structures, such asroof systems, are built to capture rain and to store the rain water forlater use. These roof systems supply an important water source forinhabitants utilizing such structures. Roof systems that are designed tocollect rain water are typically made of metal to increase the longevityof the roofing system. Typically, the roof systems are made of carbonsteel since such metal is less expensive. Terne alloy has historicallybeen used due to its relatively low cost, ease of application, excellentcorrosion-resistant properties and desirable colorization duringweathering. Roof systems have been made of other metals, but to muchless extent due to higher cost and natural corrosion resistance. Suchmetals include stainless steel, copper, copper alloys and aluminum.Stainless steel, copper, copper alloys and aluminum were typically notcoated with a terne coating since these metals have excellentcorrosion-resistant properties. However, in some limited applications,these metals have been coated with terne to extend the life of thesemetals. However, as with lead piping, thereis a concern that the lead inthe terne coated roofing materials results in lead dissolving in thecollected water.

Terne coated materials have typically been coated with a 6-8 lb. coating(7-11 microns), which is a very thin coating. This thin coating commonlyincludes pinholes. Terne coated materials that are drawn or formed invarious types of materials such as, but not limited to, gasoline tanks,corrugated roofing materials and the like typically included one or moredefects in the coating. Due to the thin layer of the terne coating andthe pinholes in the coating, the coating on the base metal, upon beingdrawn by a die or by being formed tended to tear or shear the ternecoating and/or elongate the pin holes on the coating thereby exposingthe base metal. These exposed surfaces typically corroded at a fasterrate than the unexposed surfaces. The corroded regions about the coatedareas, in some instances, compromised the adherence of the coated area,thereby resulting, in some instances, to flaking of the coated regions.These corroded regions compromised, in some instances, rapidlycompromised the structural integrity, safety and/or performance of thecoated base metal. Another disadvantage of using a terne alloy coatingis the softness of the terne layer. The softness of the terne coating issusceptible to damage from the abrasive nature of forming machines andto environments that subject the terne coating to frequent contact withother materials.

Terne alloys have a further disadvantage in that the newly applied terneis very shiny and highly reflective. As a result, in some buildingapplications, the highly reflective coating cannot immediately be used.The terne coating eventually loses its highly reflective properties asthe components of the terne coating are reduced (weathered); however,the desired amount of reduction commonly takes about 1.5 to 2 years whenthe terne coating is exposed to the atmosphere. The storage of the ternecoated base metal significantly prolongs the weathering of the ternecoated materials.

Metallic coatings such as tin or zinc have been tested as substitutesfor terne coatings with limited success. The most popular process forapplying a tin coating to a base metal is by en electroplating process.In an electroplating process, the coating thickness is very thin andtypically ranges between 0.3 microns to 30 microns. The very thinthicknesses of the tin coating typically results in a tin coating havinga network of small pinholes, thereby making the coated materialgenerally unacceptable for use in corrosive environments, such as onbuilding materials, marine materials, and automotive products. Such tinplated base metals can include a flash or intermediate metal layer(plated layer) to reduce the pinhole problems inherent with the tinplating process; however, the corrosion effectiveness of the plated tinlayer, in some applications, is less than terne coated materials. Thetin plated layer is also susceptible to flaking or being scrapped offwhen the tin plated base metal is drawn through a die and/or formed intovarious components. The flaking of the tin coating can also causepremature clogging of filter systems and liquid lines, such as ingasoline lines and filters, when the tin plated based metals are formedinto gasoline tanks. The pinholes problem, flaking and/or scrapingproblem that is associated with plated tin coatings is very problematicsince tin is not electroprotective under oxidizing conditions.Consequently, discontinuities in the plated tin coating can result inthe corrosion of the exposed base metal.

Coating a base metal with zinc metal, commonly known as galvanizing, isanother popular metal treatment to inhibit corrosion. Zinc is adesirable metal to coat materials because of its relatively low cost,ease of application, and excellent corrosion resistance. Zinc is alsoelectroprotective under oxidizing conditions and inhibits or preventsthe exposed metal, due to discontinuities in the zinc coating, fromrapidly corroding. This electrolytic protection extends away from thezinc coating over exposed metal surfaces for a sufficient distance toprotect the exposed metal at cut edges, scratches, and other coatingdiscontinuities. Although zinc coatings bond to many types of metals,the bond is typically not very strong thereby resulting in the zinccoating flaking off the base metal over time and/or when being formed.The flaking of zinc, like the flaking of tin coatings, can causepremature clogging of filter systems and liquid lines when zinc coatedbase metal is formed into gasoline tanks or used in other liquidsystems. The flaking of the zinc coating can also result in an undesiredand/or disfigured product over a short period of time. Zinc also doesnot form a uniform and/or thick coating when coating on various types ofbase metals. Zinc is also a very rigid and brittle metal, thus tends tocrack and/or flake off when the zinc coating is formed and/or drawnthrough a die. When zinc oxidizes, the zinc coating forms a whitepowdery texture (zinc oxide). This white powdery substance isundesirable for many building applications and in various otherenvironments and applications. One such coating process is disclosed inU.S. Pat. No. 5,399,376, which is incorporated herein by reference.Consequently, the use of a tin coating or a zinc coating as a substitutefor terne coatings has not been highly reliable, commercially acceptableor a cost effective substitute for traditional terne coatings. Metalcoatings that include a hot dip coating of tin and zinc alloy have beenused for fuel tanks as disclosed in Japanese Patent Application No.47-977776 filed Sep. 29, 1972. The alloy coating thickness was disclosedto be 10-15 microns.

Metal coatings that include electroplated tin and zinc have also beenused to coated base metals. Electroplating a tin and zinc mixture onto asteel sheet is disclosed in Japanese Patent Application No. 56-144738filed Sep. 16, 1981, which is incorporated herein by reference. TheJapanese patent application discloses the plating of a steel sheet witha tin and zinc mixture to form a coating thickness of less than 20microns. The Japanese patent application discloses that after plating,pinholes exist in the coating and subject the coating to corrosion. Thepin holes are a result of the crystalline layer of the tin and zincmixture slowly forming during the plating process. Consequently, theJapanese patent application discloses that the plated tin and zinccoating must be covered with chromate or phosphoric acid to fill the pinholes to prevent corrosion. The Japanese patent application disclosesthat a preplated layer of nickel, tin or cobalt on the steel sheetsurface is needed so that the plated tin and zinc mixture will adhere tothe steel sheet.

The coating of steel articles by a batch hot-dip process with a tin,zinc and aluminum mixture is disclosed in U.S. Pat. No. 3,962,501 issuedJun. 8, 1976, which is incorporated herein by reference. The '501 patentdiscloses that the tin, zinc and aluminum mixture resists oxidation andmaintains a metallic luster. The '501 patent discloses that the moltentin and zinc alloy is very susceptible to oxidation resulting in viscousoxides forming on the surface of the molten tin and zinc alloy. Theseviscous oxides cause severe problems with the coating process. While thesteel article is immersed in the molten alloy, a large amount of drossforms on the surface of the molten alloy. The dross results innon-uniformity of the coating and the formation of pin holes as thesteel article is removed from the molten metal. The '501 patentdiscloses that the addition of up to 25% aluminum to the tin and zincalloy inhibits dross formation, reduces Zn—Fe alloy formation, andreduces viscous oxide formation on the molten bath surface.

The treatment of a steel sheet by plating tin and zinc followed by heatflowing is disclosed in U.S. Pat. No. 4,999,258, which is incorporatedherein by reference. The '258 patent discloses a steel sheet plated witha layer of tin and a subsequent layer of zinc. The tin and zinc platedlayers are then heated until the zinc alloys with the tin. The tin isapplied at 0.2-1.0 g/m² and the zinc is applied at 0.01-0.3 g/m². The'258 patent also discloses that when less than 1% zinc is used, thebeneficial effect of the zinc is null; however, when more than 30% zincis used, the coating will rapidly corrode under adverse environments.The '258 patent also discloses that a nickel plated layer is preferablyapplied to the steel sheet prior to applying the tin and zinc platedlayers to improve corrosion resistance. The heat treated tin and zinclayer can be further treated by applying a chromate treatment to theplated layer further improve corrosion resistance.

Due to the various environmental concerns and problems associated withcorrosion-resistant coatings applied to base metals and the problemsassociated with the inadvertent removal of the corrosion-resistantcoating during the forming and/or drawing of the coated materials, therehas been a demand for a coating or metal material that iscorrosion-resistant, is environmentally friendly, and resists damageduring forming into end components. Many of these demands where met bythe tin alloy or the tin and zinc alloy and process and method forapplying these alloys to a base metal which is disclosed in Assignee'sU.S. Pat. Nos. 5,314,758; 5,354,624; 5,395,702; 5,395,703; 5,397,652;5,401,586; 5,429,882; 5,455,122; 5,470,667; 5,480,731; 5,489,490;5,491,035; 5,491,036; 5,492,772; 5,520,964; 5,597,656; 5,616,424;5,667,849; 5,695,822; and 6,080,497; and Assignee's U.S. patentapplication No. Ser. No. 09/634,828 filed Aug. 9, 2000, all of which areincorporated herein by reference.

The use of copper base metals for architectural materials and otherapplications present unique challenges. Copper is typically morecorrosion resistant than carbon steel in many environments. Commercialcopper is used for the roofing material and for other types ofarchitectural materials due to its desirable mechanical properties andnatural corrosive resistant properties. Copper is one of the strongestpure metals. It is moderately hard, extremely tough, and wear resistant.Though copper in its commercially pure state is very formable thusrelatively easily shaped, the copper can be further softened by anannealing process to further improve its formability. Copper alloys canalso be used in the architectural materials. Some common alloys ofcopper are copper-zinc alloys or copper-nickel alloys. Generally, thecopper alloys reduce the formability of the architectural materials.Although copper or copper alloy materials have properties that areadvantageous in various applications, when copper oxidizes, the oxideforms a black, green or blue-green layer. This color change isunacceptable in a variety of applications. Uncoated copper can also beused to collect water; however, the oxidized copper tends to mix withthe water and adversely affects the taste and color of the water. Asdisclosed in U.S. Pat. No. 5,354,624, copper base materials can becoated with a tin alloy to form a corrosion resistant material that ispliable and that resists formation of a black, green or blue-green layerduring oxidation. The life of the copper is significantly extended bycoating the copper with the tin alloy.

Due to the various environmental concerns and problems associated withcorrosion-resistant coatings applied to copper materials and theproblems associated with the forming of the coated copper material intovarious types of components, there has been a demand for a coppermaterial that is corrosion-resistant, is cost effective to use, isenvironmentally friendly, resists damage during forming, is pliable,does not oxidize to produce an undesirable color, and is not highlyreflective.

SUMMARY OF THE INVENTION

The present invention relates to a product and method of producing acorrosion-resistant, environmentally friendly metal material. Moreparticularly, the invention relates the coating of a base metal with acorrosion resistant metal alloy which forms a corrosive-resistantbarrier on the base metal. Even more particularly, the invention relatesto a copper containing base metal coated with a corrosion-resistantmetal alloy which coated base metal is formed into truck and/orautomotive products, architectural and/or building materials, householdmaterials, marine products; and/or formed into tools or machinery.

In accordance with the principal feature of the invention, there isprovided a corrosion resistant metal alloy primarily including tin andzinc. In one embodiment of the invention, the corrosion resistant metalalloy is coated on a copper containing base metal, which coated basemetal is formed, molded, and/or drawn into a metal article. The coppercontaining base metal includes pure copper base metals; copper alloybase metals (e.g. brasses, bronzes, copper-nickels, etc.); metals (e.g.stainless steel, carbon steel, nickel alloys, titanium or titaniumalloys, aluminum or aluminum alloys, tin, etc.) that are plated, clad,or otherwise coated and/or bonded with copper and/or copper alloy.

In accordance with one aspect of the invention, the corrosion resistantmetal alloy is a tin and zinc alloy. In one embodiment of the invention,the tin and zinc constituents of the tin and zinc alloy maintain theirown integrity (structure or composition) in the composite with one phasemetal being a matrix surrounding distinct globules or phases of thesecond phase metal. The tin and zinc system is a dual strata of metalglobules or phases, each globule or phase being distinct from the otherin structure or composition. The lowest weight percentage of zinc in aneutectic tin and zinc mixture is a tin rich mixture containing about90-91 weight percent tin and about 9-10 weight percent zinc. For the tinrich matrix or phase and zinc rich globules or phases to form in a tinand zinc alloy, the zinc must make up at least over about 9-10 weightpercent of the tin and zinc alloy. A zinc content over about 9-10 weightpercent of the tin and zinc alloy results in the zinc precipitating outof the tin and forming zinc globules or phases within the tin and zincalloy. The tin content of the tin and zinc alloy must be at least about15 weight percent of the tin and zinc alloy so that there is asufficient amount of tin within the tin and zinc alloy to form the tinphase about the zinc phase. A metal alloy that primarily includes tinand zinc but has a zinc content that is equal to or less than theminimum eutectic weight percentage of zinc is defined herein as a tinalloy, instead of a tin and zinc alloy. A tin and zinc alloy is definedherein as a metal alloy that includes at least about 15 weight percenttin and at least about 9-10 weight percent zinc and the tin content pluszinc content of the metal alloy constitutes at least a majority of themetal alloy. One of the important and desirable properties of the tinand zinc alloy is its excellent corrosion-resistance in many differentenvironments. The tin and zinc alloy is very corrosion resistant inmarine environments wherein chloride salts are common, and in industrialenvironments wherein sulfur and sulfur compounds are present. Theexcellent corrosion-resistance of the tin and zinc alloy is believed toresult from the formation of a stable, continuous, adherent, protectivefilm on the surface. The damaged film generally reheals itself quickly.Because of the general inertness of the film, that is at least partiallyformed of tin and zinc oxide, in most atmospheres, the corrosionresistant tin and zinc alloy is considered to be environmentally safeand friendly, and considered a safe material to be used in the humanenvironment. The tin and zinc alloy also forms over time a dull,low-reflecting surface; has a pleasing color; performs well in lowtemperatures; has a relatively low coefficient of thermal expansion;resists degradation by solar energy; can be molded, cast, formed, drawn,soldered, painted and/or colored; and/or can be installed in a varietyof weather conditions. The tin and zinc alloy is further a costeffective material for use in structures used in corrosive environmentssuch as in the tropics and other areas where buildings are exposed tostrong winds, corrosive fumes, and/or marine conditions. In anotherand/or alternative embodiment of the invention, the tin content plus thezinc content in the tin and zinc alloy makes up over 50 weight percentof the tin and zinc alloy. In one aspect of this embodiment, the tincontent plus the zinc content in the tin and zinc alloy is at leastabout 60 weight percent of the tin and zinc alloy. In another and/oralternative aspect of this embodiment, the tin content plus the zinccontent in the tin and zinc alloy is at least about 75 weight percent ofthe tin and zinc alloy. In yet another and/or alternative aspect of thisembodiment, the tin content plus the zinc content in the tin and zincalloy is at least about 80 weight percent of the tin and zinc alloy. Instill yet another and/or alternative aspect of this embodiment, the tincontent plus the zinc content in the tin and zinc alloy is at leastabout 85 weight percent of the tin and zinc alloy. In a further and/oralternative aspect of this embodiment, the tin content plus the zinccontent in the tin and zinc alloy is at least about 90 weight percent ofthe tin and zinc alloy. In yet a further and/or alternative aspect ofthis embodiment, the tin content plus the zinc content in the tin andzinc alloy is at least about 95 weight percent of the tin and zincalloy. In still a further and/or alternative aspect of this embodiment,the tin content plus the zinc content in the tin and zinc alloy is atleast about 98 weight percent of the tin and zinc alloy. In still yet afurther and/or alternative aspect of the embodiment, the tin plus zinccontent in the tin and zinc alloy is at least about 99 weight percent ofthe tin and zinc alloy.

In accordance with another and/or alternative aspect of the invention, ametal alloy is a tin alloy, as defined above, that primarily includestin, and zinc content is equal to or less than the minimum eutecticweight percentage of zinc in the tin alloy. As such, the tin alloy is ametal alloy that includes at least a majority of tin and less than 9-10weight percent zinc. The corrosion resistant tin alloy forms a corrosionresistant coating that protects the surface of the base metal fromoxidation. The corrosion resistant tin alloy provides protection to thebase metal in a variety of environments such as rural, industrial,and/or marine environments. The corrosion resistant tin alloy alsoperforms well in low temperatures; has a relatively low coefficient ofthermal expansion; has a pleasing color; resists degradation by solarenergy; can be molded, cast, formed, drawn, soldered, painted and/orcolored; and/or can be installed in a variety of weather conditions.Because of the relative inertness of the tin oxide in many environments,the corrosion resistant tin alloy is considered to be environmentallysafe and friendly and considered a safe material to be used in the humanenvironment. The corrosion resistant tin alloy is also a cost effectivematerial for use in structures erected in corrosive environments, suchas in the tropics and other areas where buildings are exposed to strongwinds, corrosive flurnes, and/or marine conditions. In one embodiment ofthe invention, the tin content in the tin alloy makes up over 50 weightpercent of the tin alloy. In one aspect of this embodiment, the tincontent in the tin alloy is at least about 75 weight percent of the tinalloy. In another and/or alternative aspect of this embodiment, the tincontent in the tin alloy is at least about 80 weight percent of the tinalloy. In yet another and/or alternative aspect of this embodiment, thetin content in the tin alloy is at least about 85 weight percent of thetin alloy. In still yet another and/or alternative aspect of thisembodiment, the tin content in the tin alloy is at least about 90 weightpercent of the tin alloy. In a further and/or alternative aspect of thisembodiment, the tin content in the tin alloy is at least about 95 weightpercent of the tin alloy. In yet a further and/or alternative aspect ofthis embodiment, the tin content in the tin alloy is at least about 98weight percent of the tin alloy. In still a further and/or alternativeaspect of this embodiment, the tin content in the tin alloy is at leastabout 99 weight percent of the tin alloy.

In accordance with yet another aspect of the invention, the corrosionresistant tin alloy and corrosion resistant tin and zinc alloy contain alow lead content. The lead source in the tin alloy or the tin and zincalloy can be from impurities in the raw tin and/or zinc ore used to makethe metal alloy, and/or can be from directed additions of lead to themetal alloy. In some metal alloy combinations, lead in the metal alloypositively affects one or more physical and/or chemical properties ofthe metal alloy. Metal alloys that include little or no lead areconsidered more environmentally friendly, and the prejudices associatedwith the lead containing alloys are overcome. When the metal alloyincludes lead, the lead content is generally at least about 0.0001weight percent of the metal alloy. In one embodiment of the invention,the tin alloy and the tin and zinc alloy include no more than about 10weight percent lead. In one aspect of this embodiment, the metal alloyinclude less than about 2 weight percent lead. In another and/oralternative aspect of this embodiment, the metal alloy include less thanabout 1 weight percent lead. In yet another and/or alternative aspect ofthis embodiment, the tin alloy and the tin and zinc alloy include lessthan about 0.5 weight percent lead. In still another and/or alternativeaspect of this embodiment, the metal alloy include less than about 0.05weight percent lead. In still yet another and/or alternative aspect ofthis embodiment, the metal alloy include less than about 0.01 weightpercent lead. In a further and/or alternative aspect of this embodiment,the metal alloy include less than about 0.005 weight percent lead. Instill a further and/or alternative aspect of this embodiment, the metalalloy include less than about 0.001 weight percent lead.

In accordance with a further and/or alternative aspect of the invention,the tin alloy and tin and zinc alloy include one or more additives. Inone embodiment of the invention, the one or more additives generallyconstitute less than about 25 weight percent of the metal alloy. In oneaspect of this embodiment, the one or more additives constitute lessthan about 10 weight percent of the metal alloy. In another and/oralternative aspect of this embodiment, the one or more additivesconstitute less than about 5 weight percent of the metal alloy. In yetanother and/or alternative aspect of this embodiment, the one or moreadditives constitute less than about 2 weight percent of the metalalloy. In still another and/or alternative aspect of this embodiment,the one or more additives constitute less than about 1 weight percent ofthe metal alloy. In still yet another and/or alternative aspect of thisembodiment, the one or more additives constitute less than about 0.5weight percent of the metal alloy. In another and/or alternativeembodiment of the invention, the additives include, but are not limitedto, aluminum, antimony, arsenic, bismuth, boron, bromine, cadmium,carbon, chlorine, chromium, copper, cyanide, fluoride, iron, lead,magnesium, manganese, molybdenum, nickel, nitrogen, phosphorous,potassium, silicon, silver, sulfur, tellurium, titanium, vanadium,and/or zinc. The one or more additives included in the corrosionresistant metal alloy are used to positively affect the chemical and/orphysical properties of the corrosion-resistant metal alloy such as, butnot limited, to enhance the mechanical properties of the alloy, toimprove corrosion resistance of the metal alloy, to improve grainrefinement of the metal alloy, to alter the color of the metal alloy, toalter the reflectiveness of the metal alloy, to inhibit oxidation of themetal alloy during forming or coating of the metal alloy and/or when themetal alloy is exposed in various types of environments, to inhibitdross formation during the forming or coating of the metal alloy, tostabilize one or more components of the metal alloy, to improve thebonding of the metal alloy on the base metal and/or intermediate barriermetal layer on the base metal, to improve the flowability of the metalalloy during the forming or coating process, to produce the thickness ofheat created intermetallic layer, and/or to reduce or inhibit thecrystallization of the tin in the metal alloy. The inclusion of one ormore additives in the corrosion resistant metal alloy typically preformone or more of the above listed functions and/or features in the metalalloy. As can be appreciated, the source or a portion of the source ofone or more of the above-listed additives in the tin alloy or tin andzinc alloy can be from impurities in the raw tin and/or zinc ore used tomake the metal alloy. The believed functions and features of selectadditives are described below; however, the described additives may haveadditional functions and features. Aluminum can reduce the rate ofoxidation of the molten metal alloy; reduce dross formation during thecoating process; alter the reflective properties of the metal alloy;alter the mechanical properties of the metal alloy (i.e. coatability,durability, flexibility, flowability, formability, hardness, andstrength); and/or reduce the thickness of the heat created intermetalliclayer to improve the formability of the coated base metal. Antimony,bismuth, cadmium, and/or copper can prevent or inhibit thecrystallization of the tin in the metal alloy, which crystallization canweaken the bonding and/or result in flaking of the corrosion resistantmetal alloy; improve the bonding properties of the metal alloy to thebase metal and/or intermediate barrier metal layer; alter the mechanicalproperties of the metal alloy; and/or alter the corrosion resistantproperties of the metal alloy. Only small amounts of antimony, bismuth,cadmium, and/or copper are needed to prevent and/or inhibit thecrystallization of the tin in the metal alloy. This small amount can beas low as about 0.001-0.05 weight percent, and typically as low as0.001-0.004 weight percent. Arsenic can alter the mechanical propertiesof the metal alloy. Cadmium, in addition to its bonding, corrosionresistant, stabilizing and/or mechanical altering properties, can reducethe rate of oxidation of the molten metal alloy; reduce dross formationduring the coating or forming process of the metal alloy; alter thecolor and/or reflective properties of the metal alloy; and/or improvethe grain refinement of the metal alloy. Chromium can provide additionalcorrosion protection to the metal alloy; alter the mechanical propertiesof the metal alloy; and/or alter the color and/or reflective propertiesof the metal alloy. Copper, in addition to its corrosion resistant,stabilizing and/or mechanical altering properties, can alter the colorand/or reflective properties of the metal alloy. Iron can alter themechanical properties of the metal alloy; and/or alter the color of themetal alloy. Lead can provide additional corrosion protection to themetal alloy; alter the mechanical properties of the metal alloy; alterthe color of the metal alloy; and/or improve the bonding properties ofthe metal alloy to the base metal and/or intermediate barrier metallayer. Magnesium can alter the mechanical properties of the metal alloy;reduce the anodic characteristics of the metal alloy; reduce the rate ofoxidation of the molten metal alloy; and/or reduce dross formationduring the forming or coating process of the metal alloy. Manganese canprovide additional corrosion protection to the metal alloy; improve thegrain refinement of the metal alloy; and/or improve the bondingproperties of the metal alloy to the base metal and/or intermediatebarrier metal layer. Nickel can provide corrosion protection to themetal alloy, especially in alcohol and chlorine containing environments;alter the mechanical properties of the metal alloy; and/or alter thecolor and/or reflective properties of the metal alloy. Silver can alterthe mechanical properties of the metal alloy; and/or alter the colorand/or reflective properties of the metal alloy. Titanium can improvethe grain refinement of the metal alloy; alter the mechanical propertiesof the metal alloy; provide additional corrosion protection to the metalalloy; reduce the rate of oxidation of the molten metal alloy; reducedross formation during the forming or coating process of the metalalloy; alter the color and/or reflective properties of the metal alloy;and/or improve the bonding properties of the metal alloy to the basemetal and/or intermediate barrier metal layer. Zinc can alter themechanical properties of the metal alloy; provide additional corrosionprotection to the metal alloy, alter the color and/or reflectiveproperties of the metal alloy; improve the bonding properties of themetal alloy to the base metal and/or intermediate barrier metal layer,and/or stabilize the tin to inhibit or prevent crystallization of thetin in the metal alloy.

In accordance with another and/or alternative aspect of the invention,the thickness of the corrosion resistant metal alloy is selected toprovide the desired amount of corrosion resistant protection to thesurface of the base metal. Generally thinner coating thicknesses can beobtained by a plating process and thicker coating thicknesses can beobtained by immersion in molten metal alloy. The selected thickness ofthe coating will typically depend on the end use of the coated basemetal and/or the environment the coated base metal is to be used. A 6lb. coating on a base metal is a common thickness for a thin coating. A6 lb. coating has a coating thickness of about 7 microns. A 6 lb.coating is commonly applied by a plating process. In many instances,very thin coatings include one or more pin holes in the coating. A 40lb. coating is also a common coating having a thickness of about 50microns. A 40 lb. coating typically has few, if any, pin holes, and dueto the thicker coating, thus the thicker coating resists tearing whenthe coated base metal is drawn or formed into various types ofcomponents. Thicker metal alloy coatings are commonly used forautomotive components (i.e. gasoline tank shell members), and roofingand siding materials. In one embodiment of the invention, the metalalloy coating is applied by a single plating process. In one aspect ofthis embodiment, the thickness of the metal alloy coating is at leastabout 1 micron. In another and/or alternative aspect of this embodiment,the thickness of the metal alloy coating is at least about 2 microns. Instill another and/or alternative aspect of this embodiment, thethickness of the metal alloy coating is about 2-30 microns. In anotherand/or alternative embodiment of the invention, the metal alloy coatingis applied by a) multiple plating processes, b) single or multiplehot-dip processes, and/or c) at least one plating process and at leastone hot dip process. In one aspect of this embodiment, the thickness ofthe metal alloy coating is at least about 1 micron. In another and/oralternative aspect of this embodiment, the thickness of the metal alloycoating is up to about 2550. In still another and/or alternative aspectof this embodiment, the thickness of the metal alloy coating is about2.5-1270 microns. In yet another and/or alternative aspect of thisembodiment, the thickness of the metal alloy coating is about 7-1270microns. In still yet another and/or alternative aspect of thisembodiment, the thickness of the metal alloy coating is about 7-1250microns. In a further and/or alternative aspect of this embodiment, thethickness of the metal alloy coating is about 15 to 1250 microns. In yeta further and/or alternative aspect of this embodiment, the thickness ofthe metal alloy coating is about 25-77 microns. In still a furtherand/or alternative aspect of this embodiment, the thickness of the metalalloy coating is about 25-51 microns.

In accordance with still another and/or alternative aspect of theinvention, the base metal is a metal strip. A “strip” is defined asmetal in the form of a thin metal sheet that is or can be rolled into aroll of metal, as opposed to plates of metal or other configurations ofthe metal. Metal strip which has a thickness of less than about 127microns (0.005 inch) can break as the strip is pretreated and/or coatedwith a metal alloy coating at high process speeds. A high process speedis defined as a metal strip moving through the pretreatment process,intermediate barrier metal coating process, and/or metal alloy coatingprocess at a speed of about 60-400 ft/mm. However, the metal stripthickness should not be too great so as to prevent the strip from beingable to be directed, at a relatively high speed, through thepretreatment process, if any, and the coating process. Metal strip whichis too thick is more difficult to heat when a heat created intermetalliclayer is to be formed between the base metal and metal alloy coatingand/or intermediate barrier metal, especially when the metal strip ismoving at high speeds and/or coated over a short period of time. Metalstrips having too great of thickness are also difficult to maneuver ateconomical high speeds through the pretreatment process, if any, and thecoating process. In one embodiment of the invention, the thickness ofthe metal strip is thin enough such that the metal strip can be unrolledfrom a roll of metal, coated by a metal alloy coating, and re-rolledinto a roll of coated metal strip. In one aspect of this embodiment, thethickness of the metal strip is not more than about 5080 microns. Inanother and/or alternative aspect of this embodiment, the thickness ofthe metal strip is less than about 2540 microns. In yet another and/oralternative aspect of this embodiment, the thickness of the metal stripis less than about 1270 microns. In still another and/or alternativeaspect of this embodiment, the thickness of the metal strip is less thanabout 762 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the metal strip is about 127-762 microns.In yet a further and/or alternative aspect of this embodiment, thethickness of the metal strip is about 254-762 microns. In still afurther and/or alternative aspect of this embodiment, the thickness ofthe metal strip is about 381-762 microns. In yet a further and/oralternative aspect of this embodiment, the thickness of the metal stripis about 127-381 microns. In still yet a further and/or alternativeaspect of this embodiment, the thickness of the metal strip is about508-762 microns. In another and/or alternative embodiment of theinvention, the thickness of the metal strip is not more than about 1588microns when the metal strip is formed of stainless steel, nickelalloys, titanium or titanium alloys. These types of metal strip aredifficult to maneuver at economical, high speeds through the coatingprocess when the metal strip thickness is greater than 1588 microns. Inone aspect of this embodiment, metal strip made primarily of stainlesssteel, nickel alloys, titanium or titanium alloy strip has a thicknessof about 127-762 microns. In another and/or alternative aspect of thisembodiment, metal strip made primarily of stainless steel, carbon steel,nickel alloys, titanium or titanium alloy strip has a thickness of about255-762 microns.

In accordance with still yet another and/or alternative aspect of theinvention, the base metal is a metal plate. In one embodiment of theinvention, the metal plate is a rectangular or square metal plate havinga length of about 1 to 15 feet and a width of about 1-20 feet. Inanother and/or alternative embodiment of the invention, the thickness ofthe metal plate is not more than about 51000 microns (2 inches). In oneaspect of this embodiment, the thickness of the metal plate is not morethan about 25400 microns. In another and/or alternative aspect of thisembodiment, the thickness of the metal plate is not more than about12700 microns.

In accordance with another and/or alternative aspect of the invention,the base metal is primarily carbon steel that has been hot dip coated,clad and/or plated with copper and/or a copper alloy. In one embodimentof the invention, the carbon steel base metal is a metal strip. In oneaspect of this embodiment, the thickness of the carbon steel strip isless than about 2540 microns. In another and/or alternative aspect ofthis embodiment, the thickness of the carbon steel strip is less thanabout 1588 microns. In yet another and/or alternative aspect of thisembodiment, the thickness of the carbon steel strip is less than about1270 microns. In still and/or alternative another aspect of thisembodiment, the thickness of the carbon steel strip is up to about 762microns. In a further and/or alternative aspect of this embodiment, thethickness of the carbon steel strip is about 127-762 microns. In yet afurther and/or alternative aspect of this embodiment, the thickness ofthe carbon steel strip is about 254-762 microns. In still a furtherand/or alternative aspect of this embodiment, the thickness of thecarbon steel strip is about 381-762 microns. In another and/oralternative embodiment of the invention, the carbon steel base metal isa metal plate. In still another and/or alternative embodiment of theinvention, the thickness of the copper and/or copper alloy on the carbonsteel base metal is less than about 2540 microns. In one aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanabout 1270 microns. In yet another and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanabout 762 microns. In still and/or alternative another aspect of thisembodiment, the thickness of the copper and/or copper alloy is about1-500 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about3-255 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-100 microns. In still a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-50 microns. In still yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-25 microns. In another and/or alternative aspect of this embodiment,the thickness of the copper and/or copper alloy is less than thethickness of the carbon steel base metal. In yet another and/oralternative embodiment of the invention, the copper and/or copper alloyis applied to the carbon steel base metal by plating. In still yetanother and/or alternative embodiment of the invention, the copperand/or copper alloy is applied to the carbon steel base metal bycladding. In a further and/or alternative embodiment of the invention,the copper and/or copper alloy is applied to the carbon steel base metalby hot dip coating.

In accordance with still another and/or alternative aspect of theinvention, the base metal is primarily stainless steel that has been hotdip coated, clad and/or plated with copper and/or a copper alloy.“Stainless steel” is used in its technical sense and includes a largevariety of ferrous alloys containing chromium and iron. Carbon steelbase metal that is plated with chromium and subsequently coated with ametal alloy coating by a hot dip process transforms the carbon steelinto stainless steel at least at the surface of the base metal surface.The stainless steel can also contain other elements or compounds suchas, but not limited to, nickel, nickel alloys, carbon, molybdenum,silicon, manganese, titanium, boron, copper, aluminum and/or variousother metals or compounds. Elements such as nickel can be flashed(plated) onto the surface of the stainless steel or directlyincorporated into the stainless steel. In one embodiment of theinvention, the stainless steel base metal is 304 or 316 stainless steel.In another and/or alternative embodiment of the invention, the stainlesssteel base metal is a metal strip. In one aspect of this embodiment, thethickness of the stainless steel strip is less than about 2540 microns.In another and/or alternative aspect of this embodiment, the thicknessof the stainless steel strip is less than about 1588 microns. In yetanother and/or alternative aspect of this embodiment, the thickness ofthe stainless steel strip is less than about 1270 microns. In stillanother and/or alternative aspect of this embodiment, the thickness ofthe stainless steel strip is up to about 762 microns. In a furtherand/or alternative aspect of this embodiment, the thickness of thestainless steel strip is about 127-762 microns. In yet a further and/oralternative aspect of this embodiment, the thickness of the stainlesssteel strip is about 254-762 microns. In still a further and/oralternative aspect of this embodiment, the thickness of the stainlesssteel strip is about 381-762 microns. In still another and/oralternative embodiment of the invention, the stainless steel base metalis a metal plate. In yet another and/or alternative embodiment of theinvention, the thickness of the copper and/or copper alloy on thestainless steel base metal is less than about 2540 microns. In oneaspect of this embodiment, the thickness of the copper and/or copperalloy is less than about 1270 microns. In yet another and/or alternativeaspect of this embodiment, the thickness of the copper and/or copperalloy is less than about 762 microns. In still and/or alternativeanother aspect of this embodiment, the thickness of the copper and/orcopper alloy is about 1-500 microns. In a further and/or alternativeaspect of this embodiment, the thickness of the copper and/or copperalloy is about 3-255 microns. In yet a further and/or alternative aspectof this embodiment, the thickness of the copper and/or copper alloy isabout 5-100 microns. In still a further and/or alternative aspect ofthis embodiment, the thickness of the copper and/or copper alloy isabout 5-50 microns. In still yet a further and/or alternative aspect ofthis embodiment, the thickness of the copper and/or copper alloy isabout 5-25 microns. In another and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanthe thickness of the stainless steel base metal. In still yet anotherand/or alternative embodiment of the invention, the copper and/or copperalloy is applied to the stainless steel base metal by plating. In afurther and/or alternative embodiment of the invention, the copperand/or copper alloy is applied to the stainless steel base metal bycladding. In still a further and/or alternative embodiment of theinvention, the copper and/or copper alloy is applied to the stainlesssteel base metal by hot dip coating.

In accordance with yet another and/or alternative aspect of theinvention, the base metal is copper. Copper metal is known for itsmalleability properties and natural corrosion resistant properties.Copper metal that is coated with a metal alloy can be formed in avariety of simple and complex shapes. In one embodiment of theinvention, the copper base metal is a metal strip. In one aspect of thisembodiment, the thickness of the copper strip is not more than about5080 microns. In another and/or alternative aspect of this embodiment,the thickness of the copper strip is less than about 2540 microns. Inyet another and/or alternative aspect of this embodiment, the thicknessof the copper strip is less than about 1270 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of thecopper strip is up to about 762 microns. In a further and/or alternativeaspect of this embodiment, the thickness of the copper strip is about127-762 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the copper strip is about 254-762 microns.In still a further and/or alternative aspect of this embodiment, thethickness of the copper strip is about 381-762 microns. In still anotherand/or alternative embodiment of the invention, the copper base metal isa metal plate.

In accordance with still yet another and/or alternative aspect of theinvention, the base metal is a copper alloy. “Copper alloys” as usedherein include, but are not limited to, brasses, bronzes, andnickel-copper alloys. Brass is defined as a copper alloy that includes amajority of copper and zinc. Bronze is defined as an alloy that includestin and a majority of copper. Brass and bronze are copper alloys withknown corrosion resistant properties in various environments. Althoughbrass and bronze are relatively corrosion resistant in manyenvironments, brass and bronze are susceptible to a greater degree ofcorrosion in some environments than others. Brass and bronze are alsorelatively bright and reflective materials which can be undesirable foruse in several applications. As a result, it has been found that brassand bronze coated with a corrosion resistant metal alloy can overcomesthese deficiencies. In one embodiment of the invention, the coppercontent of the brass is about 50.1-99 weight percent and the zinccontent is about 1-49.9 weight percent. In one aspect of thisembodiment, the brass includes one or more additives such as, but notlimited to, aluminum, beryllium, carbon, chromium, cobalt, iron, lead,manganese, magnesium, nickel, niobium, phosphorous, silicon, silver,sulfur, and/or tin. These additives typically alter the mechanicaland/or corrosion resistant properties of the brass. In another and/oralternative embodiment of the invention, the bronze includes one or moreadditives such as, but not limited to, aluminum, iron, lead, manganese,nickel, nitrogen, phosphorous, silicon, and/or zinc. In still anotherand/or alternative embodiment of the invention, the copper alloy basemetal is a metal strip. In one aspect of this embodiment, the thicknessof the copper alloy strip is not more than about 5080 microns. Inanother and/or alternative aspect of this embodiment, the thickness ofthe copper alloy strip is less than about 2540 microns. In yet anotherand/or alternative aspect of this embodiment, the thickness of thecopper alloy strip is less than about 1270 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of thecopper alloy strip is less than about 762 microns. In a further and/oralternative aspect of this embodiment, the thickness of the copper alloystrip is about 127-762 microns. In yet a further and/or alternativeaspect of this embodiment, the thickness of the copper alloy strip isabout 254-762 microns. In still a further and/or alternative aspect ofthis embodiment, the thickness of the copper alloy strip is about381-762 microns. In yet another and/or alternative embodiment of theinvention, the copper alloy base metal is a metal plate.

In accordance with a further and/or alternative aspect of the invention,the base metal is primarily made of aluminum, aluminum alloys, nickelalloys, tin, titanium, or titanium alloys that have been hot dip coated,clad and/or plated with copper and/or a copper alloy. “Aluminum alloys”as used herein include, but are not limited to, alloys including atleast about 10 weight percent aluminum. “Nickel alloys” as used hereininclude, but are not limited to, alloys including at least about 5weight percent nickel. In one embodiment of the invention, the basemetal is primarily an aluminum metal strip that has been coated, cladand/or plated with copper and/or a copper alloy. In another and/oralternative embodiment of the invention, the base metal is primarily analuminum alloy metal strip that has been coated, clad and/or plated withcopper and/or a copper alloy. In yet another and/or alternativeembodiment of the invention, the base metal is primarily a nickel alloystrip that has been coated, clad and/or plated with copper and/or acopper alloy. In still another and/or alternative embodiment of theinvention, the base metal is primarily a tin metal strip that has beencoated, clad and/or plated with copper and/or a copper alloy. In stillyet another and/or alternative embodiment of the invention, the basemetal is primarily a titanium metal strip that has been coated, cladand/or plated with copper and/or a copper alloy. In a further and/oralternative embodiment of the invention, the base metal is primarily atitanium alloy metal strip that has been coated, clad and/or plated withcopper and/or a copper alloy. In one aspect of these embodiments, thethickness of the aluminum, aluminum alloy, nickel alloy, tin, titanium,or titanium alloy strip is less than about 2540 microns. In anotherand/or alternative aspect of these embodiments, the thickness of thealuminum, aluminum alloy, nickel alloy, tin, titanium, or titanium alloystrip is less than about 1588 microns. In yet another and/or alternativeaspect of these embodiments, the thickness of the aluminum, aluminumalloy, nickel alloy, tin, titanium, or titanium alloy strip is less thanabout 1270 microns. In still another and/or alternative aspect of theseembodiments, the thickness of the aluminum, aluminum alloy, nickelalloy, tin, titanium, or titanium alloy strip is up to about 762microns. In a further and/or alternative aspect of these embodiments,the thickness of the aluminum, aluminum alloy, nickel alloy, tin,titanium, or titanium alloy strip is about 127-762 microns. In yet afurther and/or alternative aspect of these embodiments, the thickness ofthe aluminum, aluminum alloy, nickel alloy, tin, titanium, or titaniumalloy strip is about 240-762 microns. In still a further and/oralternative aspect of these embodiments, the thickness of the aluminum,aluminum alloy, nickel alloy, tin, titanium, or titanium alloy strip isabout 381-762 microns. In yet a further and/or alternative embodiment ofthe invention, the base metal is primarily an aluminum metal plate. Instill a further and/or alternative embodiment of the invention, the basemetal is primarily an aluminum alloy metal plate. In still yet a furtherand/or alternative embodiment of the invention, the base metal isprimarily a nickel alloy plate. In another and/or alternative embodimentof the invention, the base metal is primarily a tin metal plate. In yetanother and/or alternative embodiment of the invention, the base metalis primarily a titanium metal plate. In still another and/or alternativeembodiment of the invention, the base metal is primarily a titaniumalloy metal plate. In yet another and/or alternative embodiment of theinvention, the thickness of the copper and/or copper alloy on thealuminum, aluminum alloy, nickel alloy, tin, titanium, or titanium alloybase metal is less than about 2540 microns. In one aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanabout 1270 microns. In yet another and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is less thanabout 762 microns. In still and/or alternative another aspect of thisembodiment, the thickness of the copper and/or copper alloy is about1-500 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about3-255 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-100 microns. In still a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-50 microns. In still yet a further and/or alternative aspect of thisembodiment, the thickness of the copper and/or copper alloy is about5-25 microns. In another and/or alternative aspect of this embodiment,the thickness of the copper and/or copper alloy is less than thethickness of the aluminum, aluminum alloy, nickel alloy, tin, titanium,or titanium alloy base metal. In still yet another and/or alternativeembodiment of the invention, the copper and/or copper alloy is appliedto the aluminum, aluminum alloy, nickel alloy, tin, titanium, ortitanium alloy base metal by plating. In a further and/or alternativeembodiment of the invention, the copper and/or copper alloy is appliedto the aluminum, aluminum alloy, nickel alloy, tin, titanium, ortitanium alloy base metal by cladding. In still a further and/oralternative embodiment of the invention, the copper and/or copper alloyis applied to the aluminum, aluminum alloy, nickel alloy, tin, titanium,or titanium alloy base metal by hot dip coating.

In accordance with yet a further and/or alternative aspect of theinvention, the base metal is pretreated prior to applying the metalalloy to the base metal. The pretreatment of the base metal is designedto remove dirt, oil, adhesives, plastic, paper and/or other foreignsubstances from the surface of the base metal; to remove oxides andother compounds from the base metal surface; etch the base metalsurface; and/or improve the bonding of the metal alloy coating to thesurface of the base metal. The pretreatment process may include one ormore process steps depending on the surface condition of the base metal.In one embodiment of the invention, the various steps of thepretreatment process for the base metal include one or more of thepretreatment process operations disclosed in U.S. Pat. No. 5,395,702,which is incorporated herein. In another and/or alternative embodimentof the invention, the pretreatment process includes, but is not limitedto, an abrasion process; an absorbent process; solvent and/or cleaningsolution process; a low oxygen environment process; a rinse process; apickling process; a chemical activation process; and/or a flux treatingprocess. In one aspect of this embodiment, each of these pretreatmentprocess can be use singly or in combination with one another. The typeand/or number of pretreatment process used generally depends on the typeof base metal and/or condition of the base metal surface. Thepretreatment process can be applied to a portion of the base metalsurface or the complete surface of the base metal. In still anotherand/or alternative embodiment of the invention, the abrasion process,absorbent process and/or solvent or cleaning process are designed toremove foreign materials and/or oxides from the base metal surface. Inone aspect of this embodiment, the abrasion process includes, but is notlimited to, the use of brushes, scrappers and the like to mechanicallyremove oxides and/or foreign material from the surface of the basemetal. In another and/or alternative aspect of this embodiment, theabsorbent process includes, but is not limited to, the use of absorbingmaterials (i.e. towels, absorbent paper products, sponges, squeegees,etc.) to mechanically remove oxides and/or foreign material from thesurface of the base metal. In still another and/or alternative aspect ofthis embodiment, the solvent or cleaning process includes, but is notlimited to, the use of water, detergents, abrasives, chemical solvents,and/or chemical cleaners to remove oxides and/or foreign material fromthe surface of the base metal. The abrasion process, absorbent process,and/or solvent or cleaning process can be use individually or inconjunction with one another to remove foreign materials and/or oxidesfrom the base metal surface. In yet another and/or alternativeembodiment of the invention, the low oxygen environment process isdesigned to inhibit the formation and/or reformation of oxides on thesurface of the base metal. The low oxygen environment may take onseveral forms such as, but not limited to, a low oxygen-containing gasenvironment and/or a low oxygen-containing liquid environment. Examplesof gases used in the low oxygen-containing gas environments include, butare not limited to, nitrogen, hydrocarbons, hydrogen, noble gassesand/or other non-oxidizing gasses. The one or more gases partially ortotally shield oxygen and/or other oxidizing elements or compounds fromthe base metal. In one aspect of this embodiment, the lowoxygen-containing gas environment includes nitrogen. Examples of liquidsused in the low oxygen-containing liquid environment include, but arenot limited to, non-oxidizing liquids and/or liquids containing a lowdissolved oxygen content. The liquids partially or totally shield oxygenand/or other oxidizing elements or compounds from the base metal. Inanother and/or alternative aspect of this embodiment, the lowoxygen-containing liquid environment includes heated water that is atleast about 37-49° C. (100-110° F.). In still another and/or alternativeaspect of this embodiment, the low oxygen-containing environment isapplied to the base metal by spraying the low oxygen-containingenvironment onto the surface of the base metal, partially or totallyimmersing the base metal in the low oxygen-containing environment,and/or encasing the base metal in the low oxygen-containing environment.In still yet another and/or alternative aspect of this embodiment,agitators are used in the low oxygen-containing liquid environment tofacilitate in the removal of oxides and/or inhibit oxide formation onthe base metal. The agitators can include brushes which contact the basemetal. In still yet another and/or alternative embodiment of theinvention, the rinsed process is designed to remove foreign materials,oxides, pickling solution, deoxidizing agent, fluxes, solvents, and/orcleaning solutions from the surface of the base metal. In one aspect ofthis embodiment, the rinse process includes the use of a rinse solutionthat includes a low or non-oxidizing liquid. In one design of thisaspect, the low or non-oxidizing liquid includes water that is at leastabout 21° C. (70° F.). In another and/or alternative aspect of thisembodiment, the rinse solution can be applied to the surface of the basemetal by spraying the rinse solution onto the base metal and/orpartially or totally immersing the base metal in the rinse solution. Inyet another and/or alternative aspect of this embodiment, the rinsesolution is agitated to facilitate in the cleaning of the base metalsurface. In still yet another and/or alternative aspect of thisembodiment, the rinse solution is recirculated, diluted and/ortemperature is maintained during the rinsing process. In a furtherand/or alternative embodiment of the invention, the pickling process isdesigned to remove a very thin surface layer from the base metal. Theremoval of the thin layer from the base metal results in the partial ortotal removal of oxides and/or other foreign matter from the base metalsurface. The removal of the thin surface layer from the base metalcauses slight etching of the base metal surface which results in theformation of microscopic valleys on the base metal surface. Thesemicroscopic valleys increase the surface area to which the metal alloyand/or intermediate barrier metal layer can bond thereby facilitating inthe formation of a stronger bond between the base metal and the metalalloy and/or intermetallic barrier metal layer. The pickling processincludes the use of a pickling solution which can be an acidic or abasic solution. In one aspect of this embodiment, the pickling solutionis an acidic solution. The acid can be an organic acid, an inorganicacid, or combinations thereof. In one particular design of this aspect,the inorganic acid used in the pickling solution includes, but are notlimited to, hydrobromic acid, hydroiodic acid, choleic acid, perchloricacid, hydrofluoric acid, sulfuric acid, nitric acid, hydrochloric acid,phosphoric acid, and/or isobromic acid. In another and/or alternativeparticular design of this aspect, the organic acid used in the picklingsolution includes, but are not limited to, formic acid, propionic acid,butyric acid, and/or isobutyric acid. In another and/or alternativeaspect of this embodiment, the pickling solution includes a single acid.Typically, a copper or copper alloy surface can be satisfactorilycleaned or pickled with the use of a single acid. In one particulardesign of this aspect, the pickling solution only includes an inorganicacid. In still another and/or alternative aspect of this embodiment, thepickling solution includes two or more acids. In some situations, thesurface of the base metal is more difficult to clean or pickle. Picklingsolutions that include two or more acids typically can provide a morerapid oxide removal rate. In one particular design of this aspect, thepickling solution contains a combination of hydrochloric acid and nitricacid. One specific formulation of this dual acid pickling solution isthe pickling solution including about 5-25% by volume hydrochloric acidand about 1-15% by volume nitric acid. A more specific formulation ofthis dual acid pickling solution is the pickling solution includingabout 5-15% by volume hydrochloric acid and about 1-5% by volume nitricacid. A yet more specific formulation of this dual acid picklingsolution is the pickling solution including about 10% by volumehydrochloric acid and about 3% by volume nitric acid. In yet anotherand/or alternative aspect of this embodiment, the temperature of thepickling solution is maintained to obtain the desired activity of thepickling solution. In one particular design of this aspect, the picklingsolution is maintained at a temperature of above about 26° C. In anotherand/or alternative particular design of this aspect, the picklingsolution is maintained at a temperature of about 48-60° C. In yetanother and/or alternative particular design of this aspect, thepickling solution is maintained at a temperature of about 53-56° C.Higher acid concentrations and/or higher acid temperatures willtypically increase the activity and aggressiveness of the picklingsolution. In yet another and/or alternative aspect of this embodiment,the pickling solution is agitated to prevent or inhibit the picklingsolution from stagnating, varying in concentration, varying intemperature, and/or to remove gas pockets which form on the base metalsurface. In one particular design of this aspect, the pickling solutionis at least partially agitated by placing agitators in a pickling tankand/or by recirculating the pickling solution in a pickling tank.Typically, agitation brushes in the pickling tank contact the base metalas it passes through the pickling tank to facilitate in oxide removaland cleaning of the base metal surface. In a further and/or alternativeaspect of this embodiment, the base metal is exposed to the picklingsolution for a sufficient time to properly clean and/or pickle thesurface of the base metal. In one particular design of this aspect, thetotal time for pickling the base metal is less than about 10 minutes. Inanother and/or alternative particular design of this aspect, the totaltime for pickling the base metal is less than about two minutes. Instill another and/or alternative particular design of this aspect, thetotal time for pickling the base metal is less than about one minute. Instill yet another and/or alternative particular design of this aspect,the total time for pickling the base metal is about 5-60 seconds. In afurther and/or alternative particular design of this aspect, the totaltime for pickling the base metal is about 10-20 seconds. In still afurther and/or alternative aspect of this embodiment, the picklingsolution is applied to the base metal by spray jets. In yet a furtherand/or alternative aspect of this embodiment, the base metal ispartially or fully immersed in the pickling solution contained in apickling tank. In still a further and/or alternative embodiment of theinvention, the chemical activation process is designed to remove oxidesand/or foreign material from the base metal surface. In one aspect ofthis embodiment, the chemical activation process includes the subjectingof the base metal surface to a deoxidizing agent. Various types ofdeoxidizing agents may be used. In another and/or alternative aspect ofthis embodiment, the deoxidizing agent includes zinc chloride. In oneparticular design of this aspect, the deoxidizing agent includes atleast about 1% by volume zinc chloride. In another and/or alternativeparticular design of this aspect, the deoxidizing agent includes atleast about 5% by volume zinc chloride. The zinc chloride removes oxidesand foreign materials from the base metal surface and/or provides aprotective coating which inhibits oxide formation on the base metalsurface. In still another and/or alternative aspect of this embodiment,the temperature of the zinc chloride solution is at least about ambienttemperature (about 15-32° C.). In yet another and/or alternative aspectof this embodiment, the deoxidizing solution is agitated to maintain auniform solution concentration and/or temperature. In one particulardesign of this aspect, the agitators include brushes which contact thebase metal. In still yet another and/or alternative aspect of thisembodiment, small amounts of acid are included to the deoxidizingsolution to enhance oxide removal. In one particular design of thisaspect, hydrochloric acid is included to the deoxidizing solution. Inone specific formulation of this design, the deoxidizing solutionincludes about 1-50% by volume zinc chloride and about 0.5-15% by volumehydrochloric acid. In another and/or alternative specific formulation ofthis design, the deoxidizing solution includes about 5-50% by volumezinc chloride and about 1-15% by volume hydrochloric acid. In a furtherand/or alternative aspect of this embodiment, the base metal issubjected to the deoxidizing solution for less than about 10 minutes. Inone particular design of this aspect, the base metal is subjected to thedeoxidizing solution for up to about one minute. In still a furtherand/or alternative aspect of this embodiment, the deoxidizing solutionis applied to the base metal by spray jets. In yet a further and/oralternative aspect of this embodiment, the base metal is partially orfully immersed in the deoxidizing solution contained in a deoxidizingtank.

In accordance with still a further and/or alternative aspect of theinvention, one or more surfaces of the base metal is coated with anintermediate barrier metal layer prior to applying the metal alloy tothe base metal. The intermediate barrier metal layer is designed toimprove the bonding of the metal alloy coating to the surface of thebase metal. The application of an intermediate barrier metal layer canbe used as a substitute for one or more pretreatment process, or can beapplied after one or more pretreatment process have been applied to thesurface of the base metal. The intermediate barrier metal process isdesigned to coat one or more surface areas of the base metal with a thinmetal coating. The intermediate metal barrier is applied to part of orthe complete surface of the base metal by a plating process, a platingand subsequent flow heating process, a metal spraying process, a coatingroller process, an immersion process in molten metal prior to applyingthe metal alloy coating to the base metal, and/or pickling process. Theintermediate barrier metal typically provides additional corrosionresistance to the base metal in many types of corrosive environments. Inmarine environments where the coated base metal is exposed to saltand/or halogens (i.e. chlorine, fluorine, etc.), the use of anintermediate barrier metal can significantly extend the life of thecoated base metal. The use of an intermediate barrier metal can alsoenhance the bonding of the metal alloy coating to the base metal. Somebase metals may form a weaker bond with certain formulations of themetal alloy. The application of an intermediate barrier metal on part ofor the complete surface of the base metal can, in many instances,improve the strength of the bond of the metal alloy coating to the basemetal. The intermediate barrier metal includes copper and/or nickel.Other or additional metals can be included in the intermediate barriermetal, such as, but not limited to, aluminum, chromium, cobalt,molybdenum, Sn—Ni, Fe—Ni, tin, and/or zinc. Typically, one intermediatebarrier metal is formed on the surface of the base metal; however, morethan one layer of one or more intermediate barrier metals can be appliedto the surface of the base metal to form a thicker intermediate barriermetal layer, alter the composition of the intermediate barrier metallayer, alter the composition of the heat created intermetallic layer ifformed, and/or improve the bonding of the metal alloy coating to theintermediate barrier metal layer and/or base metal. In one embodiment ofthe invention, copper or a copper alloy is included in the intermediatebarrier metal. A copper or copper alloy containing intermediate barriermetal layer enhances the corrosion-resistant properties of the heatcreated intermetallic layer that is formed between the metal alloy andthe base metal, improves the bonding of the metal alloy to the basemetal, and/or improves the corrosion resistance of the metal alloyand/or coated base metal. The copper or copper ahoy in the intermediatebarrier metal can also inhibit adverse zinc crystal growth in the heatcreated intermetallic layer. A thick zinc layer can cause poor coatingquality or cracking of the coating during forming and bending, give riseto localized corrosion, and/or adversely affect performance of thecoated base metal in some applications. The copper or copper alloy istypically plated onto the surface of the base metal; however, the copperor copper alloy can be applied to the surface of the base metal by othermeans such as, but not limited to, hop dip coating, cladding or otherbonding methods. In one aspect of this embodiment, the copper or copperalloy is plated on the surface of the base metal. The plated copper orcopper alloy layer can be formed by passing the base metal through anelectroplating process or by adding copper sulfate to a picklingsolution and pickling the coated base metal. In another and/oralternative embodiment of the invention, the intermediate barrier metalincludes nickel. Typically, the nickel is flashed or plated to the basemetal surface; however, the nickel can be applied to the surface of thebase metal by other means. The nickel in the intermediate barrier metallayer improves corrosion-resistance of the base metal and/or metalalloy, especially against halogen containing compounds which canpenetrate the metal alloy coating and attack and oxidize the surface ofthe base metal thereby weakening the bond between the base metal and themetal alloy coating. The nickel in the intermediate barrier metal layerhas also been found to provide a formidable barrier to alcohols and/orvarious type of petroleum products. The metal alloy coating and nickelin the intermediate barrier metal can effectively complement one anotherto provide superior corrosion resistance. An intermediate barrier metallayer which includes nickel can also improve the bonding of the metalalloy coating to the base metal. An intermediate barrier metal layerwhich includes nickel can also inhibit the formation of a thick zinclayer in the heat created intermetallic layer. In yet another and/oralternative embodiment of the invention, the thickness of theintermediate barrier metal layer is at least about 0.3 micron. In oneaspect of this embodiment, the thickness of the intermediate barriermetal layer is at least about 1 micron. In another and/or alternativeaspect of this embodiment, the thickness of the intermediate barriermetal layer is less than about 500 microns. In yet another and/oralternative aspect of this embodiment, the thickness of the intermediatebarrier metal layer is less than about 250 microns. In still anotherand/or alternative aspect of this embodiment, the thickness of theintermediate barrier metal layer is less than about 50 microns. In stillyet another and/or alternative aspect of this embodiment, the thicknessof the intermediate barrier metal layer is less than about 20 microns.In a further and/or alternative aspect of this embodiment, the thicknessof the intermediate barrier metal layer is less than about 15 microns.In yet a further and/or alternative aspect of this embodiment, thethickness of the intermediate barrier metal layer is less than about 12microns. In accordance with still yet another and/or alternativeembodiment of the invention, the intermediate barrier metal layer isheated prior to applying the metal alloy coating to the base metal. Theheating of the intermediate barrier metal layer to a sufficienttemperature for a sufficient amount of time causes a heat createdintermetallic layer to form between the intermediate barrier metal layerand the base metal. A heat created intermetallic layer can be formedwithout the use of a subsequent heating step when the intermediatebarrier metal is applied to the base metal by a metal spraying process,a coating roller process, and/or an immersion process. The temperatureof the intermediate barrier metal in the heated or molten state causes aheat created intermetallic layer to at least partially form between theintermediate barrier metal and the base metal. A “heat createdintermetallic layer” is defined herein as a metal layer formed by heatwherein the metal layer is a mixture of at least the primary surfacecomponents of the base metal and components of a coated metal layer(i.e. intermediate barrier metal and/or metal alloy coating). Theapplication of heat to the base metal and the coated metal layer resultsin the surface of the base metal to soften and/or melt, and to combinewith a portion of the soften or melted coated metal layer. In manyinstances, the formation of a heat created intermetallic layer resultsin improved bonding of the coated metal layer to the base metal, and/orimproves the corrosion-resistance of the base metal and/or coated metallayer. Typically the temperature that the coated metal layer and/or basemetal is exposed to at least partially cause the formation of a heatcreated intermetallic layer is a temperature that at least softens thesurface of the base metal and/or the coated metal layer. In manyinstances, the melting point of the coated metal layer will be less thanthe melting temperature of the surface of the base metal. As such, thetemperature that the coated metal layer and/or base metal is exposed tois typically the temperature that at least softens the coated metallayer. For example, if the coated metal layer was plated copper, thetemperature needed to at least partially cause the formation of a heatcreated intermetallic layer would be at least about 926° C. (1700° F.),and typically at least about 1060° C. (1940° F.). In one aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is at leastabout 0.1 micron. In another and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is at leastabout 0.3 micron. In still another and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is at leastabout 0.5 micron. In yet another and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is at leastabout 1 micron. In still yet another and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is less thanabout 100 microns. In still yet another and/or alternative aspect ofthis embodiment, the thickness of the heat created intermetallic layerformed between the base metal and the intermediate barrier metal is lessthan about 50 microns. In a further and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is less thanabout 25 microns. In yet a further and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is less thanabout 20 microns. In still a further and/or alternative aspect of thisembodiment, the thickness of the heat created intermetallic layer formedbetween the base metal and the intermediate barrier metal is less thanabout 18 microns. In still yet a further and/or alternative aspect ofthis embodiment, the thickness of the heat created intermetallic layerformed between the base metal and the intermediate barrier metal is lessthan about 15 microns. In still another and/or alternative aspect ofthis embodiment, the thickness of the heat created intermetallic layerformed between the base metal and the intermediate barrier metal is lessthan about 12 microns. Typically the formation of a heat createdintermetallic layer makes at least a couple seconds to form. In stillanother and/or alternative embodiment of the present invention, the basemetal is exposed to heat for at least about 2 seconds to at leastpartially form the heat created intermetallic layer between the basemetal and the intermediate barrier metal. The time period of heatexposure for an intermediate barrier metal layer applied by a platingand/or a pickling process is the time the intermediate barrier metal isexposed to heat after the plating and/or pickling process. The timeperiod for heat exposure for an intermediate barrier metal layer appliedby metal spraying, coating rollers, and/or immersion in molten metalincludes the time of applying the intermediate barrier metal to the basemetal and the time the intermediate barrier metal is exposed to heatafter the metal spraying, coating rollers, and/or immersion in moltenmetal process. Typically, the time of total heat exposure is less thanabout four hours; however, greater heat exposure times can be used. Inone aspect of this embodiment, the total time period of heat exposure toan intermediate barrier metal layer applied to the base metal to atleast partially form an intermetallic layer between the base metal andthe intermediate barrier metal layer is less than about 20 minutes. Inanother and/or alternative aspect of this embodiment, the total timeperiod of heat exposure to an intermediate barrier metal layer appliedto the base metal to at least partially form an intermetallic layerbetween the base metal and the intermediate barrier metal layer is lessthan about 10 minutes. In yet another and/or alternative aspect of thisembodiment, the total time period of heat exposure to an intermediatebarrier metal layer applied to the base metal to at least partially forman intermetallic layer between the base metal and the intermediatebarrier metal layer is less than about 5 minutes. In still anotherand/or alternative aspect of this embodiment, the total time period ofheat exposure to an intermediate barrier metal layer applied to the basemetal to at least partially form an intermetallic layer between the basemetal and the intermediate barrier metal layer is about 0.033-2 minutes.When heat is applied to the coated base metal to form or further formthe heat created intermetallic layer between the base metal andintermediate metal barrier layer, the heat typically is applied by, butnot limited to, an oven and/or furnace, induction heating coils, lasers,heat exchanger, and/or radiation. As can be appreciated, the flowheating of the plated intermediated barrier layer can also function as apre-heat process for the base metal. Alternatively, or in addition to,the heat can be supplied by coating the base metal and the intermediatedmetal barrier layer with a metal alloy by a hot-dip process. The heatfrom the hot-dip process causes the formation of the heat createdintermetallic layer. In still another embodiment of the invention, theapplication of the intermediate barrier metal layer on the surface ofthe base metal is a partial or complete pretreatment process for thesurface of the base metal prior to applying the metal alloy coating tothe base metal. The application of the an intermediate barrier metal tothe surface of the base metal forms a clean metal surface on the basemetal surface. Due to this clean metal surface, the application of thean intermediate barrier metal to the surface of the base metal canfunction as the sole pretreatment process for the surface of the basemetal. As can be appreciated, the surface of the base metal can bepretreated with other pretreatment process prior to applying theintermediate barrier metal layer and/or pretreated with otherpretreatment process subsequent to applying the intermediate barriermetal layer.

In accordance with another and/or alternative aspect of the invention,metal alloy coating is coated on the base metal by a plating process orby a hot dip process. The coating process for the metal alloy coatingcan be by a batch or continuous process. As defined herein, a “hot dipprocess” for the metal alloy is any process that coats the metal alloycoating on the base metal and causes the at least partial formation of aheat created intermetallic layer between the base metal and the metalalloy coating. Examples of a hot dip process include, but are notlimited to, 1) plating a metal alloy coating partially or totally on thebase metal and subsequently heating the plated layer until a heatcreated intermetallic layer at least partially forms between the platedlayer and the base metal, 2) plating a metal alloy partially or totallyon the base metal and subsequent partial or total immersion of the basemetal in a molten bath of metal alloy for a sufficient period of time topartially or totally coat the base metal and to at least partially forma heat created intermetallic layer between the coated metal alloy layerand the base metal, 3) plating a metal alloy partially or totally on thebase metal and subsequent spray coating molten metal alloy onto the basemetal to partially or totally coat the base metal wherein the base metalis spray coated for a sufficient period of time to at least partiallyform a heat created intermetallic layer between the coated metal layerand base metal, 4) plating a metal alloy partially or totally on thebase metal and subsequent partial or total immersion of the base metalin a molten bath of metal alloy and spray coating molten metal alloyonto the base metal to partially or totally coat the base metal whereinthe base metal is spray coated and immersed for a sufficient period oftime to at least partially form a heat created intermetallic layerbetween the coated metal layer and base metal, 5) partial or totalimmersion of the base metal in a molten bath of metal alloy for asufficient period of time to partially or totally coat the base metaland to at least partially form a heat created intermetallic layerbetween the coated metal layer and the base metal, 6) partial or totalimmersion of the base metal in a molten bath of metal alloy for asufficient period of time to partially or totally coat the base metaland spray coating molten metal alloy onto the base metal to partially ortotally coat the base metal wherein the base metal is immersed andsprayed for a sufficient period of time to at least partially form aheat created intermetallic layer between the coated metal layer and basemetal, 7) spray coating the base metal with molten metal alloy topartially or totally coat the base metal for a sufficient period of timeto at least partially form a heat created intermetallic layer betweenthe coated metal layer and the base metal, 8) plating and subsequentheating and subsequent immersion in molten metal alloy coating and/orspray coating molten metal alloy coating to at least partially form aheat created intermetallic layer between the coated metal layer and thebase metal, 9) plating and subsequent heating and subsequent immersionin molten metal alloy coating and/or spray coating molten metal alloycoating and subsequent heating after immersion in molten metal alloycoating and/or spray coating molten metal alloy coating to at leastpartially form a heat created intermetallic layer between the coatedmetal layer and the base metal, 10) immersion in molten metal alloycoating and subsequent heating to at least partially form a heat createdintermetallic layer between the coated metal layer and the base metal,11) immersion in molten metal alloy coating and spray coating moltenmetal alloy coating and subsequent heating after immersion and spraycoating to at least partially form a heat created intermetallic layerbetween the coated metal layer and the base metal, 12) spray coatingmolten metal alloy coating and subsequent heating after spray coating toat least partially form a heat created intermetallic layer between thecoated metal layer and the base metal, 13) coating molten metal alloy bycoating rollers to at least partially form a heat created intermetalliclayer between the coated metal layer and the base metal, 14) coatingmolten metal alloy by coating rollers and spray coating to at leastpartially form a heat created intermetallic layer between the coatedmetal layer and the base metal, 15) immersion in molten metal alloy andcoating molten metal alloy by coating rollers to at least partially forma heat created intermetallic layer between the coated metal layer andthe base metal, 16) plating and coating molten metal alloy by coatingrollers to at least partially form a heat created intermetallic layerbetween the coated metal layer and the base metal, 17) coating moltenmetal alloy by coating rollers and subsequent heating to at leastpartially form a heat created intermetallic layer between the coatedmetal layer and the base metal. As can be appreciated, many other hotdip coating combinations can be used. As further can be appreciated, thebase metal can be coated a multiple times by various types of coatedprocesses. When heat is applied to the coated base metal to form orfurther form the heat created intermetallic layer between the base metaland the metal alloy coating, the heat typically is applied by, but notlimited to, an oven and/or furnace, induction heating coils; lasers,heat exchanger, and/or radiation. In one embodiment of the invention,the thickness of the heat created intermetallic layer is at least about0.3 micron. In one aspect of this embodiment, the thickness of the heatcreated intermetallic layer formed between the base metal and the metalalloy coating is at least about 1 micron. In yet another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 100 microns. In still another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 50 microns. In still yet another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 25 microns. In a further and/or alternativeaspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 20 microns. In still a further and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 18 microns. In still yet a further and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 15 microns. In still another and/oralternative aspect of this embodiment, the thickness of the heat createdintermetallic layer formed between the base metal and the metal alloycoating is less than about 12 microns. Typically, the formation of aheat created intermetallic layer takes at least a couple seconds toform. In another and/or alternative embodiment of the invention, thebase metal and/or metal alloy coating is exposed to heat for at least 2seconds to at least partially form the heat created intermetallic layerbetween the base metal and the metal alloy coating. The time period ofheat exposure of a metal alloy coating layer applied by a platingprocess is the time the metal alloy coating is exposed to heat after theplating process. The time period for heat exposure for a metal alloycoating layer applied by metal spraying, coating rollers and/orimmersion in molten metal includes the time of applying the metal ahoycoating to the base metal and the time the metal alloy coating isexposed to heat after the metal spraying, coating rollers, and/orimmersion in molten metal process. In one aspect of this embodiment, thetotal time period of heat exposure to a metal alloy coating layerapplied to the base metal to at least partially form an intermetalliclayer between the base metal and the metal alloy coating layer is lessthan about 4 hours; however, greater heat exposure times can be used. Inanother and/or alternative aspect of this embodiment, the total timeperiod of heat exposure to a metal alloy coating layer applied to thebase metal to at least partially form an intermetallic layer between thebase metal and the metal alloy coating layer is less than about 3 hours.In still another and/or alternative aspect of this embodiment, the totaltime period of heat exposure to a metal alloy coating layer applied tothe base metal to at least partially form an intermetallic layer betweenthe base metal and the metal alloy coating layer is less than about 2hours. In yet another and/or alternative aspect of this embodiment, thetotal time period of heat exposure to a metal alloy coating layerapplied to the base metal to at least partially form an intermetalliclayer between the base metal and the metal alloy coating layer is lessthan about 1 hour. In still yet another and/or alternative aspect ofthis embodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to at least partially form anintermetallic layer between the base metal and the metal alloy coatinglayer is less than about 30 minutes. In a further and/or alternativeaspect of this embodiment, the total time period of heat exposure to ametal alloy coating layer applied to the base metal to at leastpartially form an intermetallic layer between the base metal and themetal alloy coating layer is less than about 20 minutes. In yet furtherand/or alternative aspect of this embodiment, the total time period ofheat exposure to a metal alloy coating layer applied to the base metalto at least partially form an intermetallic layer between the base metaland the metal alloy coating layer is less than about 10 minutes. Instill a further and/or alternative aspect of this embodiment, the totaltime period of heat exposure to a metal alloy coating layer applied tothe base metal to at least partially form an intermetallic layer betweenthe base metal and the metal alloy coating layer is less than about 5minutes. In still yet further and/or alternative aspect of thisembodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to at least partially form anintermetallic layer between the base metal and the metal alloy coatinglayer is about 0.033-2 minutes. In another and/or alternative aspect ofthis embodiment, the total time period of heat exposure to a metal alloycoating layer applied to the base metal to at least partially form anintermetallic layer between the base metal and the metal alloy coatinglayer is about 0.033-0.5 minutes. In yet another and/or alternativeaspect of this embodiment, the total time period of heat exposure to ametal alloy coating layer applied to the base metal to at leastpartially form an intermetallic layer between the base metal and themetal alloy coating layer is about 0.083-0.5 minutes. In still yetanother and/or alternative embodiment of the invention, the metal alloycoating formed on the surface of the base metal by a batch coatingprocess or by a continuous coating process can result in different typesof coatings. These differences can include, but are not limited to, thefollowing:

-   -   a) Uniformity of coating (weight and thickness)    -   b) Surface appearance    -   c) Smoothness    -   d) Texture control    -   e) Control of intermetallic phases (growth and uniformity)

A base metal coated in a continuous coating process typically produces acoated base metal having superior uniformity of coating (weight andthickness), superior metallographic structure, superior surfaceappearance, superior smoothness, superior spangle size, and fewersurface defects. Furthermore, the composition of the heat createdintermetallic layer is typically superior as compared to a base metalcoated in a batch coating process. In addition to surface appearance anduniformity of thickness, the formability of the coated base metal isgenerally better due to a more uniform coating thickness on the surfaceof the base metal. In general, thicker coatings provide greatercorrosion protection, whereas thinner coatings tend to give betterformability and weldability. Thinner coatings with uniformity ofthickness can be better formed by a continuous coating process.

In still another and/or alternative aspect of the invention, the metalalloy coating is at least partially applied to the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or anexisting metal alloy coating by a plating process. When a platingprocess is used, a heat created intermetallic layer is not formedbetween the metal alloy coating and the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or a previouslyapplied metal alloy coating. Typically, the plating process is carriedout by standard plating processes, thus a detailed description of aplating process is not described herein. The complete or partial surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or surface of a previously applied metal alloy can be coated by theplating process. The plating of the components of the corrosionresistant metal alloy can be accomplished at the same time or insubsequent steps. For instance, a corrosion resistant tin and zinc alloywhich an be plated by a) simultaneously plating the tin and zinc ontothe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, b) first plating the tin on thesurface of the base metal, the surface of the intermediate barrier metallayer and/or metal alloy coating, and subsequently plating the zinc onthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, or c) first plating the zinc onthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or metal alloy coating, and subsequently plating thetin on the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or metal alloy coating. Similarly, a corrosionresistant tin and zinc alloy which includes antimony can be plated by a)simultaneously plating the tin, zinc and antimony onto the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, b) first plating the tin on the surface ofthe base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, then plating the zinc on the surface of thebase metal, the surface of the intermediate barrier metal layer, and/ormetal alloy coating, and subsequently plating the antimony on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, c) first plating the zinc on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, then plating the tin on the surfaceof the base metal, the surface of the intermediate barrier metal layer,and/or metal alloy coating, and subsequently plating the antimony on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, d) first plating the antimony on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or metal alloy coating, and subsequently simultaneouslyplating tin and zinc on the surface of the base metal, the surface ofthe intermediate barrier metal layer, and/or metal alloy coating, etc.In one embodiment of the invention, a tin and zinc alloy is plated onthe surface of the base metal. In one aspect of this embodiment, theplating process includes the plating of tin and zinc in an electrolyticsolution containing stannous tin, zinc and an acid.

In yet another and/or alternative aspect of the invention, the metalalloy coating is at least partially applied to the surface of the basemetal, the surface of the intermediate barrier metal layer, and/orpreviously applied metal alloy coating by a hot dip process thatincludes plating and subsequent heating of the plated metal alloy. Themetal alloy is plated onto the surface of the base metal, the surface ofthe intermediate barrier metal layer, and/or a previously applied metalalloy coating by a plating process that is the same as or similar to theplating process described above. After the metal alloy is plated ontothe surface of the base metal, the surface of the intermediate barriermetal layer, and/or previously applied metal alloy coating, the platedmetal alloy coating is subjected to heat for a sufficient period of timeand at a sufficient temperature to form a heat created intermetalliclayer between the plated metal alloy coating and the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating (i.e. flowheating). If one or more of the components of the corrosion resistantmetal alloy coating are plated by a separate plating process, the platedmetal components of the metal alloy coating can be subjected to heatafter one or more of the plating processes, or after all the componentsof the metal alloy coating have been coated onto the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating. The heating ofthe plated metal alloy coating causes at least a portion of the metalalloy to enter a softened or molten state and to form an at leastpartially uniform and substantially level coating layer. The heating ofthe plated metal alloy coating also facilitates in the reduction and/orelimination of pin holes in the metal alloy coating which may haveformed during the plating process. The time period selected for heatingthe plated metal alloy coating generally depends on the time necessaryto soften and/or melt the desired amount of metal coating to form thedesired thickness of the heat created intermetallic layer. When one ormore of the components of the metal alloy coating are plated by separateplating process, the plated metal components of the metal alloy coatingare subjected to heat for a sufficient period of time to at leastpartially alloy together the components of the metal alloy coating. Theheating process for the plated metal alloy can be by a batch or by acontinuous process. In one embodiment of the invention, the plated metalalloy coating is exposed to heat by the application of another moltenmetal alloy coating onto the surface of the plated metal alloy coating.The heat of the molten metal alloy upon contact with the plated metalalloy causes the components of the plated metal alloy coating to atleast partially alloy together and/or to at least partially form theheat created intermetallic layer between the plated metal alloy coatingand the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or the surface of the previously applied metalalloy coating. In one aspect of this embodiment, a molten metal alloy isapplied by immersion and coated onto the surface of the plated metalalloy coating. In another aspect of this embodiment, a molten metalalloy is applied by coating rollers and coated onto the surface of theplated metal alloy coating. In still another aspect of this embodiment,a molten metal alloy is applied by spray coating and coated onto thesurface of the plated metal alloy coating. In another embodiment of theinvention, the plated metal alloy coating is exposed to an external heatsource for a time period and temperature sufficient to at leastpartially alloy together the components of the plated metal alloycoating and/or to at least partially form the heat created intermetalliclayer between the plated metal alloy coating and the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating. The plated metalalloy coating is typically exposed to heat through the use of aconvection oven, a furnace, heated fluids, flames, induction heating,lasers, hot gasses, radiation, and the like. In one aspect of thisembodiment, the temperature the plated metal alloy is exposed to atemperature that is at least about 200° C. In another aspect of thisembodiment, the temperature the plated metal alloy is exposed to atemperature that is less than about 2000° C. In still another aspect ofthis embodiment, the temperature the plated metal alloy is exposed to isless than about 1000° C. In yet another aspect of this embodiment, thetemperature that the plated metal alloy is exposed to is less than about500° C.

In accordance with still yet another and/or alternative aspect of theinvention, the corrosion resistant metal alloy is at least partiallycoated onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by immersion into molten corrosion resistantmetal alloy. In one embodiment of the invention, the molten corrosionresistant metal alloy is maintained at a temperature of at least about232° C. (449° F.). In one aspect of this embodiment, the moltencorrosion resistant metal alloy is maintained at a temperature of atleast about 2-30° C. above the melting point of the corrosion resistantmetal alloy. In another embodiment of the invention, the residence timeof the base metal in the molten corrosion resistant alloy is selected toat least partially form a heat created intermetallic layer between thecorrosion resistant alloy metal coating and the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating. In one aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is at least about 0.033-0.083 minutes. In another aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is less than about 10 minutes. In still another aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is less than about two minutes. In yet another aspect ofthis embodiment, the residence time of the base metal in the moltenmetal alloy is less than about one minute. In still yet another aspectof this embodiment, the residence time of the base metal in the moltenmetal alloy is about 0.083-0.5 minutes.

In accordance with another and/or alternative aspect of the invention,the hot dip coating of the base metal by immersion in molten metal alloyincludes the use of a flux box. The flux box is designed to receive thebase metal prior to the base metal passing into the molten metal alloy.The flux solution in the flux box can be formulated to remove residualoxides from the base metal surface; shield the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating from oxygen untilthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or the surface of the previously applied metal alloycoating base metal is coated with the molten metal alloy; inhibit theformation of viscous oxides at the point where the base metal enters themolten metal alloy; and/or inhibit dross formation during the coatingprocess. The exposure of the base metal to the flux solution istypically the last pretreatment process of the base metal prior to beingcoated by immersion in molten metal alloy. In one embodiment of theinvention, the flux box contains a flux solution which has a lowerspecific gravity than the molten metal alloy, thus the flux solution atleast partially floats on the surface of the molten alloy. In anotherand/or alternative embodiment of the invention, the flux solutionincludes a zinc chloride solution. In one aspect of this embodiment, theflux solution includes ammonium chloride. In another and/or alternativeaspect of this embodiment, the flux solution includes about 20-75% byvolume zinc chloride. In yet another and/or alternative aspect of thisembodiment, the flux solution includes zinc chloride and ammoniumchloride. In still yet another and/or alternative aspect of thisembodiment, the flux solution includes about 20-75% by volume zincchloride and up to about 40% by volume ammonium chloride. In a furtherand/or alternative aspect of this embodiment, the flux solution includesabout 30-60% by volume zinc chloride and up to about 1-20% by volumeammonium chloride. In yet a further and/or alternative aspect of thisembodiment, the flux solution includes about 50% by volume zinc chlorideand about 8% by volume ammonium chloride.

In accordance with still another and/or alternative aspect of theinvention, the hot dip process of coating the base metal is by immersionin a molten metal alloy includes a melting pot for heating the moltenmetal alloy. In one embodiment of the invention, the melting pot isheated by heating coils, heating rods, gas jets, induction heating,lasers, radiation, etc. In one aspect of this embodiment, the meltingpot is heated by at least one gas jet directed toward at least one sideof the melting pot. In another and/or alternative aspect of thisembodiment, heating coils and heating rods are used to heat the metalalloy directly in the melting pot. In still another and/or alternativeaspect of this embodiment, gas jets are used heat the molten metal alloyin the melting pot.

In accordance with a further and/or alternative aspect of the invention,the hot dip process of coating the base metal by immersion in moltenmetal alloy includes the use of a protective material on at least aportion of the surface of the molten metal alloy in the melting pot. Theprotective material is formulated to at least partially shield themolten metal alloy from the atmosphere thereby preventing or inhibitingoxide formation on the surface of the molten metal alloy, and/orpreventing or inhibiting dross formation on the coated base metal as thecoated base metal enters and/or exits from the melting pot. In oneembodiment of the invention, the protective material has a specificgravity which is less than the specific gravity of the molten metalalloy so that at least a portion of the protective material at leastpartially floats on the surface of the molten metal alloy. In anotherand/or alternative embodiment of the invention, the protective materialincludes an oil. In one aspect of this embodiment, the protectivematerial includes palm oil. When the protective material is palm oil,the melting point of the metal alloy should be below about 344° C., thedegrading point of palm oil. For metal alloys having a higher meltingpoint, other oils, fluxes, or other materials and/or special coolingprocesses for the protective material are employed when a protectivematerial is used. In still another and/or alternative embodiment, theprotective material facilitates in forming a smooth and uniform coatingon the surface of the base metal.

In accordance with another and/or alternative aspect of the invention,the thickness of the metal alloy coating by immersion in molten metalalloy is at least partially regulated by the residence time of the basemetal in the molten metal alloy, the temperature of the molten metalalloy in the melting pot, and/or the speed at which the base metal movesthrough the molten metal alloy. In one embodiment of the invention, thebase metal is maintained at a substantially constant speed through themolten metal alloy. The substantially uniform speed results in asubstantially uniform growth of the heat created intermetallic layerbetween the metal alloy and the base metal, a substantially smoothcoating of metal alloy, and/or a substantially constant metal alloycoating thickness. As the base metal passes through the molten metalalloy at a substantially constant speed, the metal alloy adheres to themoving base metal and shears a portion of the metal alloy coating fromthe moving base metal. The shearing effect results from the viscosity ofthe molten alloy and the speed of the moving base metal. For a givenspeed and metal alloy viscosity, a certain thickness of metal alloy willbe applied to the base metal over a given time. The shearing effectresults in a substantially uniform coating, excellent surfaceappearance, excellent smoothness, excellent texture control and asubstantially uniform heat created intermetallic layer. In anotherand/or alternative embodiment of the invention, the base metal is coatedby moving the base metal through the molten metal alloy in the meltingpot at a relatively constant speed of about 1-400 ft/min. In one aspectof this embodiment, the base metal is moved through the molten metalalloy in the melting pot at a relatively constant speed of about 50-250ft/min.

In accordance with still another and/or alternative aspect of theinvention, the corrosion resistant metal alloy is at least partiallycoated onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a coating roller process. Molten metalalloy on the coating rollers is applied to the surface of the basemetal, the surface of the intermediate barrier metal layer, and/or thesurface of the previously applied metal alloy coating by a coatingroller process as the base metal passes by or between one or morecoating rollers. The coating rollers form a substantially smooth and/oruniform metal alloy coating layer on the base metal. One or more coatingrollers at least partially press against and coat the surface of thebase metal, the surface of the intermediate barrier metal layer, and/orthe surface of the previously applied metal alloy coating; and/or fillpinholes or uncoated surfaces on the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating by a coating. roller process.The coating rollers can also control the thickness of the metal alloycoating onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a coating roller process. In oneembodiment of the invention, one or more coating rollers are used inconjunction with an immersion process and/or metal spray process. Inanother and/or alternative embodiment, at least two coating rollers arespaced apart a sufficient distance so that the base metal can passbetween the coating rollers. As the base metal basses between one ormore coating rollers, the coating rollers maintain a desired coatingthickness of the metal alloy on the base metal, remove excess metalalloy from the base metal, and/or coat any non-coated regions on thesurface of the base metal. In one aspect of this embodiment, the coatingthickness of the metal alloy is selected to ensure that essentially nouncoated regions exist on the surface of the base metal. Typically, theaverage thickness of the metal alloy on the surface of base metal is atleast about 1 micron, and generally at least about 2.5 microns, moregenerally about 7 to 2550 microns, and even more generally about 7-1270microns. In another and/or alternative aspect of this embodiment, thecoating thickness of the metal alloy is selected to ensure the coatedmetal alloy has essentially no pin holes, and/or does not shear whenformed into various products. A metal alloy coating thickness of about25-51 microns forms a coating that has few, if any, pin holes, providesgreater elongation characteristics, and resist shearing when formed intovarious shaped articles; however, thinner coating may include few, ifany, pin holes. In still another and/or alternative aspect of thisembodiment, the thickness of the metal alloy is selected for use incertain types of environments in which the coated base metal is to beused. A metal alloy coating thickness of about 25-51 microns forms acoating that significantly reduces the corrosion rate of the base metalin virtually all types of environments; however, thinner coatings cansignificantly reduces the corrosion rate of the base metal. Metal alloycoating thicknesses greater than about 51 microns are typically used inharsh environments to provide added corrosion protection. In yet anotherand/or alternative embodiment of the invention, the molten metal alloyis maintained at a temperature at least about 2-30° C. above the meltingpoint of the metal alloy, while the metal alloy is on the coatingrollers. In still yet another and/or alternative embodiment of theinvention, the coating process includes at least one set of coatingrollers that partially or fully coat the surface of the base metal asthe base metal passes the coating rollers. In a further and/oralternative embodiment of the invention, one or more coating rollers areat least partially immersed in molten metal alloy during the coatingprocess. In one aspect of this embodiment, the coating process is usedin conjunction with an immersion coating process one or more of thecoating rollers are at least partially immersed in molten metal alloy inthe melting pot. In another and/or alternative aspect of thisembodiment, one or more of the coating rollers are at least partiallyimmersed in a protective material in the melting pot. In yet a furtherand/or alternative embodiment of the invention, one or more coatingrollers are positioned above the molten metal alloy in the melting potwhen the coating rollers are used in conjunction with an immersioncoating process. In still a further and/or alternative embodiment of theinvention, one or more coating rollers are at least partially coatedwith molten metal alloy by one or more spray jets that directs moltenmetal alloy on to the one or more coating rollers. The one or more sprayjets at least partially direct the molten metal alloy on to the surfaceof the coating rollers as the base metal passes by or between thecoating rollers thereby resulting in the base metal being partially orcompletely coated with the metal alloy. In still a further and/oralternative embodiment of the invention, one or more coating rollersinclude an internal cavity in which molten metal alloy is directed intoand then directed onto the surface of the coating roller which at leastpartially directs the molten metal alloy on to the surface of thecoating rollers as the base metal passes by or between the coatingrollers. In still yet a further and/or alternative embodiment of theinvention, the time period the base metal is exposed to each coatingroller is a relatively short time. The time period is dependant on thespeed of the base metal and the size of the coating rollers. Typically,the base metal is exposed to the coating rollers for at least about 0.3seconds and generally about 0.5-30 seconds. In another and/oralternative embodiment of the invention, one or more coating rollersinclude one or more grooves. The one or more grooves are designed tofacilitate in maintaining the molten metal alloy on the coating rollerduring the coating process.

In accordance with yet another and/or alternative aspect of the presentinvention, the corrosion resistant metal alloy is at least partiallycoated onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by a spray coating process. Molten metalalloy is sprayed onto the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy coating by one or more spray jets. The spray jetsspray molten metal alloy onto the surface of the base metal, the surfaceof the intermediate barrier metal layer, and/or the surface of thepreviously applied metal alloy coating to at least partially coat thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy coating,and/or ensure that a uniform and/or continuous coating is applied on thesurface of the base metal, the surface of the intermediate barrier metallayer, and/or the surface of the previously applied metal alloy coating.The speed and time the surface of the base metal, the surface of theintermediate barrier metal layer, and/or the surface of the previouslyapplied metal alloy is in contact with the molten metal can becontrolled so that the desired coating thickness and/or desiredthickness of the heat created intermetallic layer is obtained. In oneembodiment of the invention, the spray jets are used in conjunction withcoating rollers and/or an immersion process. In one aspect of thisembodiment, the spray jets at least partially direct molten metal alloyonto the coating rollers and/or onto the surface of the base metal, thesurface of the intermediate barrier metal layer, and/or the surface ofthe previously applied metal alloy coating during the coating process.In another and/or alternative embodiment of the invention, the moltenmetal alloy is maintained at a temperature of at least about 2-30° C.above the melting point of the metal alloy as the metal alloy is sprayedfrom the one or more spray jets. In yet another and/or alternativeembodiment of the invention, the base metal passes by or between one ormore metal spray jets during the coating process to partially orcompletely coat the surface of the base metal. In still another and/oralternative embodiment of the invention, the base metal is exposed tothe molten metal alloy from the one or more metal spray jets for asufficient time to partially or fully coat the surface of the basemetal. The time the base metal is exposed to the molten metal alloy fromthe metal spray jets is dependent on the speed of the moving base metal.Typically, the base metal is exposed to the molten metal alloy from themetal spray jets for at least about 0.3 seconds, generally about 0.5-60seconds, and typically about 1-30 seconds.

In accordance with another and/or alternative aspect of the presentinvention, the coated base metal which is coated by a hot dip process issubjected to an air-knife process. In an air-knife process, the coatedmetal alloy is subjected to a high velocity fluid. The high velocityfluid removes surplus molten corrosion resistant metal alloy coatingfrom the surface of the base metal, the surface of the intermediatebarrier metal layer, and/or the surface of the previously applied metalalloy coating; smears the coated corrosion resistant metal alloy overthe surface of the base metal, the surface of the intermediate barriermetal layer, and/or the surface of the previously applied metal alloycoating thereby reducing or eliminating pin holes or other uncoatedsurfaces; improves the grain size of the coated metal alloy; smoothsand/or reducing lumps or ribs in the coated metal alloy; reduces themetal alloy coating thickness; and/or cools and/or hardens the moltenmetal alloy. In one embodiment of the invention, the air knife processuses a high velocity fluid which generally does not oxidize thecorrosion resistant alloy. In one aspect of this embodiment, the fluidused in the air-knife process includes, but is not limited to, an inertor substantially inert gas such as, but not limited to, nitrogen, sulfurhexafluoride, carbon dioxide, hydrogen, noble gases, and/orhydrocarbons. In another and/or alternative embodiment of the invention,the high velocity fluid of the air-knife process is directed onto bothsides of the coated base metal and at a direction which is notperpendicular to the surface of the coated base metal. In still anotherand/or alternative embodiment of the invention, the protective materialon the surface of the molten metal alloy in the melting pot iseliminated when the air-knife process is used in conjunction with acoating process by immersion in molten alloy. When an air-knife processis used in conjunction with coating by immersion, the inert orsubstantially inert fluid inhibits or prevents dross formation and/orviscous oxide formation in the region in which the inert orsubstantially inert fluid contacts the molten metal alloy in the meltingpot. The high velocity of the inert or substantially inert fluid alsobreaks up and/or pushes away dross or viscous oxides on the surface ofthe molten metal alloy thus forming a dross and oxide free region forthe coated base metal to be removed from the melting pot. In yet anotherand/or alternative embodiment of the invention, the air-knife processincludes one or more blast nozzles to direct a high velocity fluidtoward the metal alloy coating on the surface of the base metal. In oneaspect of this embodiment, the coated base metal is directed between twoor more blast nozzles. In still yet another and/or alternativeembodiment, the air-knife process at least partially causes molten metalalloy on the surface of the base metal to be directed back into themelting pot when the air-knife process is used in conjunction with animmersion coating process. In a further and/or alternative embodiment,one or more blast nozzles are adjustable so as to direct the highvelocity fluid at various angles onto the surface of the coated basemetal. In yet a further and/or alternative embodiment of the invention,one or more blast nozzles are partially or fully enclosed in a chamber,which chamber is designed to accumulate or trap at least a portion ofthe fluid after the fluid is directed toward the base metal. Theaccumulated fluid can then be recirculated back through the blastnozzles. In still a further and/or alternative embodiment of theinvention, the air-knife process is used to control the thickness and/orquality of the molten metal alloy coating. In still yet a further and/oralternative embodiment of the invention, the base metal is exposed tothe fluid from the air-knife process for a relatively short period oftime. The time the base metal is exposed to the fluid can be dependenton the speed of the moving base metal. Typically, the base metal isexposed to the fluid from the air-knife process for at least about 0.3seconds, generally about 0.5-60 seconds, and typically about 1-30seconds.

In accordance with another and/or alternative aspect of the presentinvention, the coated base metal is cooled by a cooling process.Typically the coated base metal is cooled after being coated by a hotdip coating process. The coated base metal can be cooled by sprayingwith and/or subjecting the coated base metal to a cooling fluid and/orimmersing the coated base metal in a cooling fluid. As previouslystated, when an air-knife process is used, the coated base metal can beat least partially cooled by the fluid from the air-knife process. Whenthe heated corrosion resistant metal alloy slowly cools, larger grainsizes and lower grain densities generally occur in the corrosionresistant metal alloy coating, and the corrosion resistant metal alloycoating typically forms a more reflective surface. When the heatedcorrosion resistant metal alloy rapidly cools, fine grain sizes and/orincreased grain densities occur in the corrosion resistant metal alloycoating, and the corrosion resistant metal alloy coating typically formsa less reflective surface than a slowly cooled corrosion resistant alloycoating. Small grain sizes and/or higher grain densities in thecorrosion resistant metal alloy coating typically result in a strongerbonding coating and greater corrosion resistance. In one embodiment ofthe invention, the cooling process is less than about two hours. In oneaspect of this embodiment, the cooling process is less than about onehour. In another and/or alternative aspect of this embodiment, thecooling process is less than 10 minutes. In still another and/oralternative aspect of this embodiment, the cooling process is less thanabout 5 minutes. In another and/or alternative embodiment of theinvention, a liquid or gas is jet sprayed onto the surface of the coatedbase metal to cool the metal alloy coating. In one aspect of thisembodiment, the cooling fluid is water. In another and/or alternativeaspect of this embodiment, the temperature of the cooling fluid is about15-95° C. In yet another and/or alternative aspect of this embodiment,the temperature of the cooling fluid is about 20-60° C. In yet anotherand/or alternative aspect of this embodiment, the temperature of thecooling fluid is about ambient temperature (20-28° C.). In still yetanother and/or alternative aspect of this embodiment, the coated basemetal is at least partially guided by a camel-back guide as the coatedbase metal is cooled by the spray jets. The camel-back guide is designedto minimize contact with the coated base metal thereby reducing theamount of metal alloy coating inadvertently removed from the base metal.In one aspect of this embodiment, the camel-back design allows coolingfluid to be applied to both sides of the coated base metal. In stillanother and/or alternative embodiment of the invention, the coated metalalloy is cooled by immersion in a cooling fluid. Typically, the coatedbase metal is directed into a cooling tank that contains a coolingfluid. In one aspect of this embodiment, the temperature of the coolingfluid in the cooling tank is maintained at a desired temperature by useof agitators, heat exchangers, and/or replenishment of cooling fluid. Inanother and/or alternative aspect of this embodiment, the temperature ofthe cooling fluid is about 15-95° C. In yet another and/or alternativeaspect of this embodiment, the temperature of the cooling fluid is about20-60° C. In yet another and/or alternative aspect of this embodiment,the temperature of the cooling fluid is about ambient temperature(20-28° C.:). In still yet another and/or alternative aspect of thisembodiment, water is used as the cooling fluid. The oxygen in the watercan cause discoloration of the metal alloy coating thereby reducing thereflectiveness of the metal alloy coating. In a further and/oralternative embodiment of the invention, the metal alloy is cooled at asufficient rate so as to control the grain size of the zinc crystal. Inone aspect of this embodiment, the metal alloy is cooled at a rate suchthat there are no more than about 40 zinc crystals in the metal alloyhave a maximum dimension of over about 400 μm within a 0.25 mm² regionof the metal alloy. In one aspect of this embodiment, the metal alloy iscooled at a sufficient rate such that there are no more than about 30zinc crystals in the metal alloy have a maximum dimension of over about400 μm within a 0.25 mm² of the metal alloy. In still another and/oralternative aspect of this embodiment, the metal alloy is cooled at asufficient rate such that there are no more than about 20 zinc crystalsin the metal alloy have a maximum dimension of over about 400 μm withina 0.25 mm² region of the metal alloy. In yet another and/or alternativeaspect of this embodiment, the metal alloy is cooled at a sufficientrate such that there are no more than about 30 zinc crystals in themetal alloy have a maximum dimension of over about 300 μm within a 0.25mm² region of the metal alloy. In still yet another and/or alternativeaspect of this embodiment, the metal alloy is cooled at a sufficientrate such that there are no more than about 20 zinc crystals in themetal alloy have a maximum dimension of over about 300 μm within a 0.25mm² region of the metal alloy. In a further and/or alternative aspect ofthis embodiment, the metal alloy is cooled at a sufficient rate suchthat there are no more than about 10 zinc crystals in the metal alloyhave a maximum dimension of over about 300 μm within a 0.25 mm² regionof the metal alloy. In still a further and/or alternative aspect of thisembodiment, the metal alloy is cooled at a sufficient rate such thatthere are no more than about 10 zinc crystals in the metal alloy have amaximum dimension of over about 200 μm within a 0.25 mm² region of themetal alloy.

In accordance with another and/or alternative aspect of the invention,the coated base metal is passed through a leveler whereby the coatedmetal alloy is molded about the base metal, and/or smoothed. In oneembodiment of the invention, a final coating thickness is obtained bythe leveler. In another and/or alternative embodiment of the invention,the leveler includes a plurality of rollers. In yet another and/oralternative embodiment of the invention, the base metal is maintained ata tension as it is passed through the leveler. In still another and/oralternative embodiment of the invention, the surface coarseness Ra ofthe metal alloy is less than about 5 μm. In one aspect of thisembodiment, the surface coarseness Ra of the metal alloy is less thanabout 4 μm. In another and/or alternative aspect of this embodiment, thesurface coarseness Ra of the metal alloy is less than about 0.01-4 μm.In another and/or alternative aspect of this embodiment, the surfacecoarseness Ra of the metal alloy is less than about 0.05-3 μm.

In accordance with yet another and/or alternative aspect of theinvention, the coated base metal is rolled into a coil for laterprocessing or use.

In accordance with still another and/or alternative aspect of theinvention, the coated base metal is sheared into specific length platesor strip for later use or immediate processing. In one embodiment of theinvention, a shearing device shears a continuously moving coated basemetal. In one aspect of this embodiment, the shearing device moves withthe moving coated base metal when shearing.

In accordance with still yet another and/or alternative aspect of thepresent invention, the heat created intermetallic layer formed betweenthe metal alloy coating and the surface of the base metal, surface ofthe intermediate barrier metal layer, and/or surface of a previouslyapplied metal alloy coating is at least partially exposed. The exposedheat created intermetallic layer has been found, in some situations, toprovide excellent corrosion resistance in a number of environments. Theheat created intermetallic layer can be exposed by mechanical and/orchemical processes. In one embodiment of the invention, at least aportion of the metal alloy coating is removed by a mechanical processthat includes, but is not limited to, grinding, melting, shearing andthe like. In another and/or alternative embodiment of the invention, atleast a portion of the metal alloy coating is removed by a chemicalprocess which includes, but is not limited to, an oxidation process. Theoxidation process at least partially removes the coated metal alloy andat least partially exposes the heat created intermetallic layer. Theoxidation process includes the use of an oxidizing solution. In oneaspect of this embodiment, the oxidation solution is selected to beautocatalytic in that the oxidation solution removes the metal alloycoating but does not or only very slowly removes the heat createdintermetallic layer. In another and/or alternative aspect of thisembodiment, the oxidation solution includes nitric acid and/or chromicacid. When nitric acid is included in the oxidation solution, the nitricacid concentration is generally about 5-60% by volume and typicallyabout 10-25% by volume of the oxidation solution. In still anotherand/or alternative aspect of this embodiment, the oxidation solutionincludes copper sulfate. When copper sulfate is included in theoxidation solution, the copper sulfate is generally less than about 10%by volume, typically about 0.5-2% by volume of the oxidation solution,and more typically about 1% by volume of the oxidation solution. In yetanother and/or alternative aspect of this embodiment, the exposure ofthe coated base metal to the oxidation solution in the oxidation processis generally less than about one hour; however, longer times can be useddepending on the concentration and temperature of the oxidationsolution, the type of metal alloy, the thickness of the metal alloy,and/or the degree of desired exposure of the heat created intermetalliclayer. In one non-limiting design of this aspect, the exposure to theoxidation solution in the oxidation process is less than about tenminutes. In another and/or alternative non-limiting design of thisaspect, the exposure to the oxidation solution in the oxidation processis less than about two minutes. In still another and/or alternativenon-limiting design of this aspect, the exposure to the oxidationsolution in the oxidation process is about 0.08-1.5 minutes. In afurther and/or alternative aspect of this embodiment, after a sufficientamount of the heat created intermetallic layer is exposed by theoxidation solution, the oxidation solution is removed from the basemetal and/or the base metal is removed from the oxidation solution. Instill a further and/or alternative aspect this embodiment, thetemperature of the oxidation solution is about 15-80° C. In onenon-limiting design of this aspect this embodiment, the temperature ofthe oxidation solution is about 30-80° C. In another and/or alternativenon-limiting design of this aspect, the temperature of the oxidationsolution is about 15-60° C. In still another and/or alternativenon-limiting design of this aspect, the temperature of the oxidationsolution is about 12-62° C. In yet another and/or alternativenon-limiting design of this aspect, the temperature of the oxidationsolution is about 40-60° C. In still yet another and/or alternativenon-limiting design of this aspect, the temperature of the oxidationsolution is about 22-42° C. In a further and/or alternative design ofthis aspect, the temperature of the oxidation solution is about 32° C.In still yet a further and/or alternative aspect of this embodiment, theoxidation solution is at least partially rinsed off after theintermetallic layer is exposed. In still another and/or alternativeembodiment of the invention, one non-limiting method of at leastpartially removing the metal alloy coating is described in U.S. Pat. No.5,397,652, which is incorporated herein.

In accordance with another and/or alternative aspect of the presentinvention, the exposed heat created intermetallic layer is at leastpartially passivated by a passivation process. The passivation processis designed to at least partially react with the heat createdintermetallic layer and to form a thin corrosion resistant layer. Thecorrosion resistant layer typically exhibits improved corrosionresistant properties, improved abrasion resistance, improved hardness,improved formality, resists cracking, and/or has less reflective coloras compared to a non-passified intermetallic layer. The passivationprocess includes the use of a passivation solution. In one embodiment ofthe invention, the passivation solution includes a nitrogen containingcompound. In another and/or alternative embodiment of the invention, thepassivation solution is the same as the oxidation solution, thus theoxidation/passivation solution removes the metal alloy to expose theheat created intermetallic layer and subsequently passifies the exposedheat created intermetallic layer to form the corrosion resistant layer.In one aspect of this embodiment, the oxidizing solution fully orsubstantially ceases to react with the intermetallic layer after thepassivation later is formed (auto-catalytic). In another and/oralternative embodiment of the invention, the coated base metal materialis at least partially passivated in a different tank from the oxidationsolution. In yet another and/or alternative embodiment of the invention,the oxidation solution and/or passivation solution is at least partiallyrinsed off the coated base metal after the formation of the passivationlayer. In still yet another and/or alternative embodiment of the presentinvention, the pacified intermetallic layer exhibits excellentformability characteristics. The formability of the base material havinga pacified intermetallic layer on the surface of the base material canexhibit improved formability characteristics. The improved formabilityis believed to be at least partially the result of the complete orpartial removal of the metal alloy from the surface of the basematerial. The removal of the metal alloy reduces the thickness of thetreated base material. In yet another and/or alternative embodiment ofthe invention, the thickness of the passivation layer is at least about0.1 micron. In one aspect of this embodiment, the thickness of thepassivation layer is about 0.1-5 microns. In another and/or alternativeaspect of this embodiment, the thickness of the passivation layer is upto about 1.5 microns.

In accordance with still another and/or alternative aspect of thepresent invention, the coated base metal is at least partially treatedwith a weathering agent to accelerate the weathering, discoloration ofthe surface of the metal alloy coating, and/or control the formation ofwhite rust on the surface of the metal alloy coating. In one embodimentof the invention, the weathering material is applied to the metal alloycoating to oxidize the metal alloy coating surface, reduce thereflectivity of the metal alloy coating, and/or discolor the metal alloycoating. In another and/or alternative embodiment of the invention, theweathering material is an asphalt-based paint which causes acceleratedweathering of the metal alloy coating when exposed to the atmosphere.The asphalt-based paint decreases the weathering time of the metal alloycoating. In one aspect of this embodiment, the asphalt paint is apetroleum-based paint which includes asphalt, titanium oxide, inertsilicates, clay, carbon black or other free carbon and an anti-settlingagent. In another and/or alternative aspect of this embodiment, theasphalt-based paint is applied at a thickness to form a semi-transparentor translucent layer over the metal alloy coating. In one non-limitingdesign of this aspect, the thickness of the asphalt-based paint is about1-500 microns. In another and/or alternative non-limiting design of thisaspect, the thickness of the asphalt-based paint is about 6-150 microns.In still another and/or alternative non-limiting design of this aspect,the thickness of the asphalt-based paint is about 6-123 microns. In yetanother and/or alternative non-limiting design of this aspect, thethickness of the asphalt-based paint is about 12-50 microns. In stillyet a further and/or alternative non-limiting design of this aspect, thethickness of the asphalt-based paint is about 12-25 microns. In stillyet another and/or alternative embodiment of the invention, theweathering agent is at least partially dried by air drying and/or byheating lamps.

In accordance with yet another and/or alternative aspect of the presentinvention, the base metal coated with the metal alloy coating isimmediately formed, or formed at a manufacturing site, or formed at abuilding site. In one embodiment of the invention, the coated base metalis formed into roofing materials such as disclosed in, but not limitedto, gutter systems or roofing material which are illustrated in U.S.Pat. Nos. 4,987,716; 5001,881; 5,022,203; 5,259,166; and 5,301,474, allof which are incorporated herein by reference. In one aspect of thisembodiment, the roofing materials are formed on site. In another and/oralternative embodiment of the invention, the coated base metal is formedinto an automotive part such as, but not limited to, a gasoline tank. Inone aspect of this embodiment, the gasoline tank includes a first andsecond metal shell member. The two combined cavities of the shellmembers are combined to form an inner fuel receiving chamber which holdsfuel within the receptacle. The abutting peripheral edges of the shellmembers are joined together and sealed to maintain the fuel within theinner petroleum receiving chamber. The two shell members can be joinedin any of a number of ways that will securely prevent the shells fromseparating and petroleum from leaking from the interior chamber (i.e.welding, soldering and/or bonding the edges together). Such a fuel tankis illustrated in U.S. Pat. No. 5,455,122, which is incorporated hereinby reference. In one aspect of this embodiment, a tin-zinc coated basemetal is used to at least partially for the gasoline tank, and any otherreceptacle or component that is exposed to petroleum products. It hasbeen found that when a tin-zinc coating or a tin alloy that includes asignificant amount of zinc is applied to a copper or copper alloy basemetal, or a non-copper or non-copper alloy base metal that has a coppersurface (e.g., plated, clad, hot dipped, brazened, etc.), the zinc atleast partially migrates from the tin and zinc alloy or tin alloy andcombines with the copper to form a corrosion resistant copper-zinc heatcreated intermetallic layer. The layer above the heat createdintermetallic layer is primarily tin and the remaining zinc content ofthe original tin zinc alloy or tin alloy. It has been found that usingtin and zinc alloys or tin alloys containing about 5-65 zinc, a highlycorrosion resistant copper-zinc alloy and a upper layer that primarilyincludes tin and a number of zinc globules or fingers. The top coatingwhich primarily includes tin results in little, if any, oxidation of thetin. In the past, when zinc was exposed to petroleum products, the zincformed a white chalky surface layer. The upper layer of the presentinvention which primarily includes tin resists or prevents the formationof this white chalky surface layer. In addition, the copper-zincintermetallic layer provides added corrosion resistence in otherenvironments. As a result, the inner surface of the petroleum receptacleresists corrosion due to the high tin content of the upper layer, andthe outer surface of the petroleum receptacle resists corrosion from theoutside elements due to the tin and zinc in the upper layer and thecopper-zinc intermetallic layer below the upper layer. Consequently,this coating provides enhanced corrosion resistance for petroleumreceptacles.

In accordance with still yet another and/or alternative aspect of thepresent invention, the base metal coated with the metal alloy coating iscoated with a sealant or protective layer. The protective layer can bechromate film, and/or an organic-inorganic composite film. In oneembodiment of the invention, the protective coating is typicallyformulated to have a high compatibility with the metal alloy layer. Inanother and/or alternative embodiment of the invention, the protectivelayer is also typically formulated to cover imperfections in the metalalloy coating (e.g. pin holes, uncoated regions, etc), and/or toprovided additional corrosion resistance to the metal alloy coating. Instill another and/or alternative embodiment of the invention, theorganic-inorganic composite film includes acrylic, polyester and/orepoxy resins. In one aspect of this embodiment, the one or more resinsare used as a solvent type or a water soluble type and in the form ofthe organic-inorganic composite resin. In another and/or alternativeaspect of this embodiment, the organic-inorganic composite film includeschromium, silicon, phosphorus and/or manganese compounds these compoundscan improve adhesion, corrosion resistance and/or weldability coatedmetal alloy. In one non-limiting formulation, the chromium compound isadded in the form of chromic acid and/or a chromate. In another and/oralternative non-limiting formulation, the silicon compound is added assilicon oxides and/or silicon fluorides. In still another and/oralternative non-limiting formulation, the phosphorus compound is addedas organic or inorganic phosphoric acids and/or phosphates. In stillanother and/or alternative embodiment of the invention, the sealant orprotective coating includes an inorganic phosphate coating. Thephosphate coating be used separately or serve as a base for the laterapplication of a siccative organic coating composition such as paint,lacquer, varnish, primer, synthetic resin, enamel, and the like. Suchcoatings are disclosed in U.S. Pat. Nos. 3,454,483; 3,620,949;3,864,230; 4,007,102; 4,165,242; Re 27,896; and 5,603,818, which areincorporated herein by reference. In still another and/or alternativeembodiment of the invention, the protective coating is has a thicknessof about 1-150 microns, and typically about 1-50 microns. In still yetanother and/or alternative embodiment of the invention, the protectivelayer is at least partially dried by air drying and/or by heating lamps.

In accordance with yet another and/or alternative aspect of the presentinvention, the metal alloy and/or coated base metal base material can beformed on site without the metal alloy cracking and/or flaking off.

In accordance with still another and/or alternative aspect of thepresent invention, the metal alloy is formed into a corrosion-resistantstrip or sheet. In one embodiment of the invention, the metal alloystrip is formed by a roll forming process. In the roll forming process,a vat of molten metal alloy is provided. The molten alloy is thendirected through a series of rollers until the desired thickness of themetal alloy strip or sheet is obtained.

The primary object of the present invention is the provision of a metalalloy having corrosion-resistant properties.

Another and/or alternative object of the present invention is theprovision of a base metal coated with a metal alloy having corrosionresistant properties.

Still another and/or alternative object of the present invention is theprovision of a coated base metal which is both corrosion-resistant andenvironmentally-friendly.

Still yet another and/or alternative object of the present invention isthe provision of a coated base metal having a sufficient coatingthickness to reduce or eliminate pinholes in the coating and/or whichthe shearing of the coating is inhibited when the coated base metal isformed.

Another and/or alternative object of the present invention is theprovision of a coated base metal having a heat created intermetalliclayer formed between the base metal and the metal alloy coating.

Yet another and/or alternative object of the present invention is theprovision of a coated base metal at least partially coated by a hot dipprocess.

Still another and/or alternative object of the present invention is theprovision of at least partially coating a base metal by a platingprocess.

Yet still another and/or alternative object of the present invention isthe provision of a base metal coated by a continuous process.

Still yet another and/or alternative object of the present invention isthe provision of a coated base metal which is formed and sheared intovarious building and roofing components, automotive components, marineproducts, household materials, and other formed materials that aresubsequently assembled on site or in a forming facility.

Another and/or alternative object of the present invention is theprovision of a coated base metal that is corrosion-resistant and whichcan be formed into complex shapes and/or ornamental designs.

Another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy which includes a coloringagent to alter the color of the corrosion resistant metal alloy, acorrosion-resistance agent to improve the corrosion-resistance of thecorrosion resistant metal alloy, a mechanical agent to improve themechanical properties of the corrosion resistant metal alloy, a grainagent to positively affect grain refinement of the corrosion resistantmetal alloy, an oxidation agent to reduce oxidation of the moltencorrosion resistant metal alloy, an inhibiting agent to inhibit thecrystallization of the corrosion resistant metal alloy, and/or a bondingagent to improve the bonding characteristics of the corrosion resistantmetal alloy.

Still another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy which includes a majorityof tin.

Yet another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy which includes a majorityof tin and zinc.

Another and/or alternative object of the present invention is theprovision of applying an intermediate barrier metal layer to the surfaceof the base metal prior to applying the corrosion resistant metal alloycoating.

Still yet another and/or alternative object of the invention is theprovision of a coated base metal which is economical to produce.

Another and/or alternative object of the invention is the provision of acoated base metal that can be soldered with conventional tin-leadsolders or no-lead solders.

Yet another and/or alternative object of the present invention is theprovision of pretreating the base metal prior to coating the base metalwith a corrosion resistant alloy to remove oxides and/or foreignmaterials from the surface of the base metal.

Another and/or alternative object of the present invention is theprovision of pickling the base metal to remove surface oxides on thebase metal prior to coating the base metal with a metal alloy.

Yet another and/or alternative object of the present invention is theprovision of chemically activating the base metal to remove surfaceoxides on the base metal prior to coating the base metal with a metal.

Still yet another and/or alternative object of the present invention isthe provision of reducing the oxygen interaction with the base metalprior to and/or during the coating process.

Another and/or alternative object of the present invention is theprovision of abrasively treating the surface of the base metal prior tocoating the base metal with a metal alloy.

Still yet another and/or alternative object of the present invention isthe provision of a metal coating that is not highly reflective.

Yet another and/or alternative object of the present invention is theprovision of a metal coating for a base metal which has a low leadcontent.

Still yet another and/or alternative object of the present invention isthe provision of using spray jets to spray molten metal alloy onto thesurface of the base metal to at least partially coat the surface of thebase metal.

Another and/or alternative object of the present invention is theprovision of coating a metal coating with a weathering agent toaccelerate the dulling of the surface of the metal alloy.

Still another and/or alternative object of the present invention is theuse of an air-knife process to at least partially control the thicknessand quality of the metal alloy coating on the base metal.

Yet still another and/or alternative object of the present invention isthe provision of cooling the metal alloy and/or a metal coating to formfine and/or high density grains which produce a strong bonding,corrosive-resistant, and/or discolored coating.

Another and/or alternative object of the present invention is theprovision of at least partially subjecting the coated base metal to anoxidation solution to at least partially remove the metal alloy from thebase metal and to at least partially expose the heat createdintermetallic layer.

Still another and/or alternative object of the present invention is theprovision of subjecting the heat created intermetallic layer to apassivation solution to form a highly corrosion-resistant,non-reflective surface layer on the base metal.

Still yet another and/or alternative object of the present invention isthe provision of a metal alloy coating which has superior corrosivecharacteristics permitting a thinner coating of the metal alloy to thebase metal than that which is required for conventional terne coatingswith the high lead content.

Still yet another and/or alternative object of the present invention isthe provision of using spray jets which at least partially spray metalalloy onto the coating rollers and/or base metal surface to reduce oreliminate non-coated surfaces on the base metal.

Another and/or alternative object of the present invention is theindirect heating of the melting pot without use of heating coils orheating rods.

Another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy that can be coated on anumber of different base metal compositions.

Yet another and/or alternative object of the present invention is theprovision of a corrosion resistant metal alloy that can be coated on abase metal having a number of different shapes.

Still another and/or alternative object of the present invention is theprovision of providing a coated base metal which is formed by acontinuous, hot dip process wherein the base metal has a controlledresidence time when exposed to the molten metal alloy.

Still yet another and/or alternative object of the present invention isthe provision of producing a highly corrosion-resistant coated basematerial that has a desired zinc crystal size in the metal alloy.

A further and/or alternative object of the present invention is theprovision of producing a highly corrosion-resistant coated base materialthat includes a desired surface smoothness.

Still a further and/or alternative object of the present invention isthe provision of producing a highly corrosion-resistant coated basematerial that includes a protective coating on the surface of the metalalloy.

Yet a further and/or alternative object of the present invention is theprovision of producing a highly corrosion-resistant coated base materialthat includes an intermetallic layer that includes a majority of copperand zinc.

Still yet a further and/or alternative object of the present inventionis the provision of producing a highly corrosion-resistant coated basematerial that is economical to make.

These and other objects and advantages will become apparent to thoseskilled in the art upon the reading and following of this descriptiontaken together with the accompanied drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings, which illustrate variousembodiments that the invention may take in physical form and in certainparts and arrangements of parts wherein;

FIGS. 1A-1B is a cross-sectional view of a hot dip process wherein ametal strip is coated with a corrosion resistant alloy by immersing themetal strip in molten corrosion resistant metal alloy;

FIG. 2 is a cross-section view of additional and/or alternativeprocesses for handling the coated metal strip;

FIG. 3 is a cross-sectional view of the process of plating a metal stripwith a corrosion resistant metal alloy;

FIG. 4 illustrates a cross-sectional view of the process of flow heatingthe plated metal alloy;

FIG. 5 illustrates a cross-section view of an alternative process ofcooling the hot-dip coated base metal in a cooling tank;

FIG. 6 illustrates a cross-sectional view of an alternative process ofusing metal spray jets during the hot-dip coating process to coat themetal strip;

FIG. 7 illustrates a cross-sectional view of an alternative process ofusing an air-knife during the hot-dip coating process to control thethickness of the coating on the metal strip;

FIG. 8 illustrates a cross-sectional view of an alternative process ofcooling the hot-dip metal alloy coated base metal by spray jets;

FIG. 9 illustrates a cross-sectional view of an alternative process ofusing abrasion treaters in conjunction with a low oxygen environment topre-treat the base metal;

FIG. 10 is a frontal view of a camel-back guide;

FIG. 11 is a prospective view of a melting pot heated by gas torches;

FIG. 12 is a cross-sectional view of a coated metal strip having aheat-created intermetallic layer;

FIG. 13 illustrates a cross-sectional view of an alternative process ofusing an oxidation process and rinse process to at least partiallyremove the metal alloy coating from the base metal to at least partiallyexpose the heat created intermetallic layer;

FIG. 14 is a cross-sectional view of a coated metal strip having aheat-created intermetallic layer and passivated surface layer.

FIG. 15 illustrates a cross-sectional view of an alternative process ofcoating a base metal by a hot dip process wherein a base metal strip isunrolled and coated by immersing the metal strip in a molten pot ofmolten alloy and then subjecting the metal strip to coating rollers andan air-knife process and then rolling the coated metal strip into acoil;

FIG. 16 is a plane view of a gasoline tank formed from the metal alloyor base metal coated with the metal alloy of the present invention;

FIG. 17 illustrates the joining of the first and second shell members ofthe gasoline tank at the peripheral edges;

FIG. 18 is a partial cross-sectional view of a gasoline tankillustrating a corrosion resistant coating on the metal shell after acoated base metal shell has been drawn;

FIG. 19 is a perspective view of a pair of adjacent roofing panelsformed from the metal alloy or base metal coated with the alloy of thepresent invention;

FIG. 20 is a cross-sectional view showing the initial assembly of theroofing panels of FIG. 19;

FIG. 21 is a cross-sectional view of the process of roll forming themetal alloy of the present invention into a metal alloy strip;

FIG. 22 is a illustration of a copper base metal coated on both sideswith a tin and zinc metal alloy; and,

FIG. 23 is an enlarged portion of the copper base metal coated with atin and zinc alloy that illustrates the heat created intermetallic layerand the surface layer and a spectral analysis of the heat createdintermetallic layer and the surface layer of the coated copper basemetal.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, wherein the showings are for the purposeof illustrating preferred embodiments of the invention only and not forthe purpose of limiting the same, reference is first had to FIGS. 1A-1Bwhich illustrates one type of hot-dip process for coating a metal alloyon a base metal and for forming a heat created intermetallic layerbetween the metal alloy coating and the base metal. However, as will belater discussed, the base metal can be alternatively coated by a processthat does not form a heat created intermetallic layer between the metalstrip and metal alloy coating. The base metal and process used to coatand/or pre-treat the base metal are illustrated in FIGS. 1-15. The basemetal is in the form of a metal strip; however, other forms of the basemetal can be used (i.e. metal plates, metal strip or metal plate formedinto various shapes, various shaped metal objects) and be coated with ametal alloy in accordance with the present invention.

The metal alloy is a corrosion resistant alloy. When the metal alloy iscoated onto the surface of a base metal, the metal alloy inhibits orprevent the base metal from corroding when exposed to the atmosphere.The metal alloy is highly corrosive resistant. The metal alloy is alsotypically abrasive resistant, pliable, weldable and/or environmentallyfriendly. The metal alloy binds with the base metal to form a durableprotective coating which is not easily removable.

The amount of corrosion resistance protection provided by the metalalloy is of primary importance. The coating of the base metal with themetal alloy functions to form a barrier to the atmosphere and/orsurrounding environment which inhibits or prevents the base metal fromcorroding. By coating the base metal with the metal alloy, the life ofthe base metal is extended for many years. The pliability of the metalalloy is also important when the coated base metal is to be formed. Formaterials such as, but not limited to, wall systems, roofing systems andpetroleum receptacles, the coated base metal is formed into variousshapes and is usually folded to form seams to bind together the coatedbase metal components. A metal coating on the base metal that forms arigid or brittle coating can crack and/or prevent the coated base metalcomponents from being properly shaped. The metal alloy of the presentinvention can be formulated to facilitate in the forming of a coatedbase metal. The metal alloy can also be formulated to be connectedtogether by solder or a weld.

Base metal, such as, but not limited to, carbon steel, stainless steel,copper, copper alloys, aluminum and aluminum alloys, oxidize whenexposed to the atmosphere and/or various types of chemicals or petroleumproducts. Over a period of time, the oxidized base metal can begin toweaken and disintegrate. The application of a corrosion resistant metalalloy onto the base metal acts as a barrier to the atmosphere,environment, and/or chemical or petroleum products to inhibit or preventthe oxidation of the base metal. By coating the base metal with thecorrosion resistant metal alloy, the life of the base metal can beextended for many years.

As illustrated in FIGS. 1A-1B, abase metal in the form of a metal strip12 is typically provided from a large metal roll 10. Metal strip 12 hasa thickness of less than about 12700 microns, and typically about127-5080 microns; however, other metal strip thickness can be useddepending on the type of base metal and the use of the coated basemetal. Metal strip 12 is typically carbon steel, stainless steel,aluminum, aluminum alloy, copper or a copper alloy. Metal strip 12 isunwound from roll 10 at speeds which are generally less than about 400ft./min., typically about 1-150 feet, more typically about 70-250ft./min., and yet more typically about 50-115 ft/min. The metal stripspeed is ultimately selected so that the residence time of the metalstrip in contact with the molten metal alloy is sufficient to coat thedesired amount of strip to a desired thickness and to form a heatcreated intermetallic layer of a desired thickness.

After metal strip 12 is unrolled from metal roll 10, metal strip 12 isoptionally pretreated prior to being coated with the metal alloy. Asillustrated in FIGS. 1A-1B, metal strip 12 is pretreated to clean and/orremove surface oxides from the surface of the metal strip prior to themetal strip being coated with the corrosion resistant metal alloy. Thetype and number of pretreatment process for metal strip 12 will dependon the surface condition of the metal strip. Typically carbon steel andstainless steel are subjected to one or more pretreatment process steps.

Metal strip 12 is illustrated in FIGS. 1A and 9 as being at leastpartially cleaned by an abrasion treater 14 after being unrolled frommetal roll 10. The abrasion treater includes brushes 16 that are drivenby motors. The brushes are placed in contact with metal strip 12 toremove foreign materials from the surface of metal strip 12, and/or toinitially etch and/or mechanically remove oxides from the surface ofmetal strip 12. Brushes 16 are typically biased against metal strip 12to cause friction between the brushes and metal strip 12, which frictionfacilitates in the cleaning and/or etching of the surface of metal strip12. Typically, brushes 16 are located on the top and bottom surface ofstrip 12. As can be appreciated, the brushes can be positioned to onlycontact a portion of the surface of the metal strip. Brushes 16 aretypically made of a material having a hardness equal to or greater thanmetal strip 12 so that the brushes will not quickly wear down whenremoving foreign materials and/or pre-etching the surface of metal strip12. In one non-limiting arrangement, the brushes are made of a metalmaterial such as, but not limited to, carbon steel wire brushes. Brushes16 typically rotate in a direction that is opposite of the direction ofthe moving metal strip. This opposite rotational direction of thebrushes causes increased abrasive contact with the surface of the metalstrip. The abrasion treatment of the metal strip surface can alsoinclude the use of absorbents, cleaners and/or solvents. Theseabsorbents, cleaners and/or solvents can be applied to part of or to thefull surface of metal strip 12 before, during and/or after metal strip12 is treated with brushes 16. The cleaners and/or solvents can include,but are not limited to, alkaline cleaners, acidic cleaners and/ororganic solvents. Typically a carbon steel strip or stainless steelstrip is subjected to the abrasion treater, and/or absorbents, cleanersand/or solvents.

After metal strip 12 passes through abrasion treater 14, if suchabrasion treater is used, metal strip 12 can be guided by strip guides13 to a low oxygen environment 20. As shown in FIGS. 1A and 9, stripguides 13 are positioned throughout the pretreatment and coatingprocesses to at least partially guide metal strip 12 through eachprocess. Low oxygen environment 20 is illustrated as being a low oxygengas environment that at least substantially surrounds the surface ofmetal strip 12 with low oxygen-containing gas 22. As can be appreciated,the low oxygen gas environment can be designed to only partially protectone or more surfaces of metal strip 12. The low oxygen-containing gasincludes, but are not limited to, nitrogen, hydrocarbons, hydrogen,noble gases and/or other non-oxygen containing gases. The lowoxygen-containing gas surrounds metal strip 12 and forms a barrieragainst the oxygen containing atmosphere thereby preventing orinhibiting oxide formation on the surface of metal strip 12. As can beappreciated, low oxygen environment 20 can include or in the alternativebe a low oxygen liquid environment. In a low oxygen liquid environment,the liquid can be sprayed on to one or more surfaces of the metal stripor the metal strip can be partially or fully immersed in the lowoxygen-containing liquid. Typically a carbon steel strip or stainlesssteel strip is subjected to the low oxygen gas environment.

Metal strip 12, after passing through low oxygen gas environment 20, ifsuch low oxygen environment is used, enters pickling tank 30 whichcontains a pickling solution 32. The pickling solution is formulated toremove surface oxides from the metal strip surface, remove dirt andother foreign materials from the metal strip surface and/or etch thesurface of the metal strip. Pickling tank 30 is of sufficient length anddepth to allow for complete immersion of metal strip 12 in picklingsolution 32 and to maintain the metal strip in contact with the picklingsolution for a sufficient period of time. Typically, pickling tank 30 isat least about 25 feet in length. As can be appreciated, the picklingtank can be longer or shorter depending on the speed of the metal strip.Furthermore, the pickling tank can be designed so that only a portion ofthe surface of metal strip 12 contacts the pickling solution. Thepickling solution typically contains one or more acids. The acidsinclude organic and/or inorganic acids. Such acids include, but are notlimited to, perchloric acid, hydrofluoric acid, sulfuric acid, nitricacid, hydrochloric acid, phosphoric acid, and/or isobromic acid.Typically, pickling solution 32 includes hydrochloric acid. Generally,the pickling solution contains at least about 5% by volume hydrochloricacid. For metal strip having extensive surface oxides and/or difficultto remove surface oxides such as, but not limited to, stainless steelstrip, an aggressive pickling solution can be used. One type ofaggressive pickling solution is a dual acid solution of hydrochloricacid and nitric acid. Formulations of the hydrochloric-nitric acidinclude a) about 1-30% by volume hydrochloric acid and about 0.1-15% byvolume nitric acid, b) about 5-25% by volume hydrochloric acid and 1-15%by volume nitric acid, and c) about 10% hydrochloric acid and 3% nitricacid. Pickling solution 32 is maintained at a temperature to obtain thedesired activity of the pickling solution. Typically, pickling solution32 is maintained at a temperature of at least about 26° C., generallyabout 48-60° C., and typically about 53-56° C. Pickling tank 30 is shownas containing one or more agitators 34; however, such agitators are notrequired. Agitator 34 is designed to agitate pickling solution 32 tomaintain a uniform solution concentration, maintain a uniform solutiontemperature and/or break up gas pockets which form on the surface ofmetal strip 12. Agitator 34 typically includes an abrasive materialwhich can both agitate pickling solution 32 and remove of oxides frommetal strip 12 when in contact with the surface of the metal strip.Agitator 34 is typically made of a material which does not react withpickling solution 32 and resists undue wear when in contact with themetal strip surface. Metal strip 12 is typically not exposed to thepickling solution for more than about 10 minutes so as to avoid pittingof the metal strip surface; however, longer pickling times can be useddepending on the type of pickling solution, concentration andtemperature of the pickling solution, type of metal strip, and/orcondition of metal strip surface. Typically, the pickling time is lessthan about ten minutes, more typically less than about two minutes,still more typically less than about one minute, and yet more typicallyabout 10-20 seconds. A pickling solution vent 36 is typically placedabove pickling tank 30 to collect and remove acid fumes and other gassesescaping pickling tank 30. Typically a carbon steel strip or stainlesssteel strip is subjected to a pickling solution.

As illustrated in FIG. 1A, metal strip 12 enters another low oxygenenvironment 20 after exiting pickling tank 30. After metal strip 12exits pickling tank 30, the surface of metal strip 12 is essentiallyabsent surface oxides and other foreign materials and is highlysusceptible to oxidation with oxygen and other gases in the atmosphere.Low oxygen environment 20 shields the surface of metal strip 12 fromoxygen and other oxidizing gases and/or liquids thereby inhibiting oxideformation on the metal strip surface. Low oxygen environment 20 is a lowoxygen-containing gas environment similar to the low oxygen environmentused after the abrasion treatment process; however, a lowoxygen-containing liquid environment could be used in conjunction withor as an alternative to the low oxygen-containing gas environment.Typically a carbon steel strip or stainless steel strip is subjected tothe low oxygen gas environment.

After metal strip 12 exits low oxygen environment 20, metal strip 12enters rinse tank 40 which contains a rinse solution 42. Rinse tank 40is designed to remove any remaining pickling solution 32 on the surfaceof metal strip 12 and/or inhibit the formation of oxides on the metalstrip surface. One type of rinse solution includes water that isdeoxygenated by heating the water above about 38-43° C. (100-110° F.).As can be appreciated, other rinse liquids can be used. Rinse solution42 can remove small amounts of oxides that remain on the surface ofmetal strip 12. The rinse solution typically is slightly acidic due tothe acidic pickling solution that is removed from the metal stripsurface. As can be appreciated, the rinse solution can be alternativelyor additionally acidified by the intentional addition of acid to therinse solution. The slightly acidic rinse solution 42 removes smallamounts of oxides on the surface of metal strip 12. Rinse tank 40 is ofsufficient length and depth to facilitate complete immersion of metalstrip 12 in rinse solution 42 and to maintain the metal strip in contactwith the rinse solution for a sufficient period of time. Typically,rinse tank 40 is at least about 20 feet in length. Metal strip 12 istypically not resident in the rinse tank for more than about 10 minutes;however, longer rinsing times can be used. As can be appreciated, therinse tank can be longer or shorter depending on the speed of the metalstrip. Furthermore, the rinse tank can be designed so that only aportion of the surface of metal strip 12 contacts the rinse solution.The rinse tank typically includes one or more agitators, not shown. Theagitators are designed to agitate rinse solution 42 to maintain auniform solution concentration, maintain a uniform solution temperature,and/or break up gas pockets which form on the surface of metal strip 12.The agitators typically include an abrasive material which can bothagitate the rinse solution and remove remaining oxides on the surface ofmetal strip 12 when in contact with the surface of the metal strip. Theagitators are typically made of a material which does not react withrinse solution 42 and resists undue wear when in contact with the metalstrip surface. As can be appreciated, the metal strip can bealternatively or additionally rinsed by spraying a rinse fluid onto aportion or the full surface of metal strip 12. Typically a carbon steelstrip or stainless steel strip is subjected to the rinse solution afterbeing subjected to a pickling solution.

Referring now to FIG. 1B, metal strip 12 enters low oxygen environment50 after exiting rinse tank 40. Low oxygen environment 50 is a lowoxygen-containing liquid environment which includes spray jets 52. Sprayjets 52 are located on each side of metal strip 12 so as to direct thelow oxygen-containing liquid onto both sides of metal strip 12. As canbe appreciated, the spray jets can be positioned about metal strip 12 sothat only a portion of the strip surface is subjected to the lowoxygen-containing liquid. The low oxygen-containing liquid 56 inhibitsoxide formation of the metal strip surface. Spray jets 52 also removeany remaining pickling solution 32 or other acid on the surface of metalstrip 12. Low oxygen-containing liquid 56 is typically heated waterhaving a temperature of at least about 38-43° C. (100-110° F.). As canbe appreciated, other low oxygen-containing liquids can be used.Furthermore, it can be appreciated that low oxygen environment 50 caninclude or in the alternative be a low oxygen-containing gasenvironment.

Metal strip 12, upon leaving low oxygen liquid environment 50, enterschemical activation tank 60 which includes a chemical activatingsolution or deoxidizing solution 62. The chemical activation tank is ofsufficient length and depth to facilitate complete immersion of metalstrip 12 in deoxidizing solution 62 and to maintain the metal strip incontact with the deoxidizing solution for a sufficient period of time.Typically, chemical activation tank is at least about 25 feet in length.As can be appreciated, the chemical activation tank can be longer orshorter depending on the speed of the metal strip. Furthermore, thechemical activation tank can be designed so that only a portion of thesurface of metal strip 12 contacts the deoxidizing solution. Thechemical activation tank typically includes one or more agitators, notshown. The agitators are designed to agitate deoxidizing solution 62 tomaintain a uniform solution concentration, maintain a uniform solutiontemperature and/or break up gas pockets which form on the surface ofmetal strip 12. The agitators typically include an abrasive materialwhich can agitate the deoxidizing solution and/or remove remainingoxides on the surface of metal strip 12 when in contact with the surfaceof the metal strip. The agitators are typically made of a material whichdoes not react with deoxidation solution and resists undue wear when incontact with the metal strip surface. The metal strip is generallysubjected to the deoxidizing solution for less than about 10 minutes,and typically less than about one minute; however, longer times can beused. Deoxidizing solution 62 is formulated to remove remaining oxideson the surface of metal strip 12 and/or act as a protective coating toinhibit oxide formation on the surface of metal strip 12. Thetemperature of the deoxidizing solution is maintained at a temperatureto achieve sufficient activity of the deoxidizing solution. Typically,the temperature of the deoxidizing solution is maintained at least about15° C., typically about 15-33° C., and more typically about 26-33° C.The deoxidizing solution typically includes zinc chloride; however,other chemical compounds can be used. Small amounts of an acid can beadd to the deoxidizing solution to further enhance oxide removal fromthe metal strip surface. One specific deoxidizing solution formulationincludes at least about 1% by volume zinc chloride. Another specificdeoxidizing solution formulation includes about 5-50% by volume zincchloride. Yet another specific deoxidizing solution formulation includesabout 5-50% by volume zinc chloride and about 0.5-15% by volumehydrochloric acid.

After metal strip 12 exits chemical activation tank 60, metal strip 12enter the final pretreatment step of immersion in a flux solution 74contained in flux box 72. As can be appreciated, metal strip 12 can beexposed to a low oxygen environment, not shown, prior to entering fluxsolution 74 to inhibit or prevent oxide formation on the metal stripsurface after the metal strip exits chemical activation tank 60. As alsocan be appreciated, flux box 72 can be designed so that only a portionof metal strip 12 is exposed to flux solution 74. Flux box 72 is locatedin melting pot 70. The flux solution in flux box 72 has a specificgravity that is less than or equal to the specific gravity of moltencorrosion resistant metal alloy 76 so that flux solution 74 at leastpartially floats on the surface of the molten corrosion resistant metalalloy. Flux solution 74 typically includes zinc chloride and ammoniumchloride; however, other compounds can be used. Specific non-limitingformulations of flux solution 74 include a) about 20-75% by volume zincchloride and 1-40% by volume ammonium chloride, b) about 20-75% byvolume zinc chloride and 1-20% by volume ammonium chloride, c) about30-60 weight percent zinc chloride and up to about 40 weight percentammonium chloride, d) about 30-60 weight percent zinc chloride and about5-40 weight percent ammonium chloride, and e) about 50 weight percentzinc chloride and about 8 weight percent ammonium chloride. As can beappreciated, other concentrations of these two components can be used.Flux solution 74 is the final pre-treating process of metal strip 12 forremoval of remaining oxides on the surface of metal strip 12 prior tobeing coated with metal alloy 76. Flux box 74 also acts as a barrier tooxygen and prevents or inhibits oxides from forming on the surface ofthe metal strip and on the surface of the molten metal alloy covered bythe flux solution.

The one or more pretreatment processes described above may or may not beused for a particular type of metal strip. For example, carbon steelstrip may only be pickled and rinsed prior to being coated with a metalalloy. Stainless steel strip may be subjected to all of the pretreatmentprocess set forth above prior to being coated with a metal alloy. Copperstrip may only be rinsed prior to being coated with a metal alloy. Asset forth above, the use of one or more of the pretreatment processes asset forth above is generally dependent on the type of metal strip, thecondition the metal strip is in after being unrolled from metal roll 10,and/or type of pretreatment processes selected from the metal strip(e.g. if pickling is selected, then a rinse process is also used).

An additional or alternative pretreatment process is the coating ofmetal strip 12 with an intermediate barrier metal layer prior to coatingthe metal strip with the corrosion resistant metal alloy. The coating ofthe metal strip with an intermediate barrier metal layer can constitutethe only pretreatment process for the metal strip, or the metal stripcan be pretreated with one or more other pretreatment process beforeand/or after the metal strip is coated with an intermediate barriermetal layer. The intermediate barrier metal layer is typically a thinlayer of metal such as, but not limited to, tin, nickel, copper,chromium, aluminum, cobalt, molybdenum, Sn—Ni, Fe—Ni, and/or zinc. Thethickness of the layer is generally less than about 500 microns andtypically less than about 100 microns. The intermediate barrier metallayer can be applied by an electroplating process as illustrated in FIG.3, an electroplating process and subsequent heating of the plated layer,immersion in molten metal, metal spraying, coating rollers, and thelike. The process for plating the intermediate barrier metal layer ontothe surface of metal strip 12 is typically by a conventional continuousplating process. The applied intermediate barrier metal layer typicallyforms a strong bond with the metal strip, whether or not the stripsurface has been pretreated with one or more other pretreatmentprocesses. The bonding of the intermediate barrier metal layer to thestrip is enhanced by heating the intermediate barrier metal layer andthe forming a heat created intermetallic layer between the metal stripand the intermediate barrier metal layer. When the intermediate barriermetal layer is plated and then flow heated, the thickness of theintermediate barrier metal layer is typically at least about 2 micronsso that a sufficiently thick intermediate barrier metal layer exists forproper flow heating. The selection of metal of the intermediate barriermetal layer can advantageously change the composition of the heatcreated intermetallic layer thereby improving corrosion resistance,improving metal alloy bonding, improve metal alloy pliability, and/orinhibiting the formation of a thick zinc layer in the intermetalliclayer when zinc is included in the metal alloy. In one specificnon-limiting embodiment of the invention, a non-copper metal strip ornon-copper alloy metal strip is coated with copper or copper alloy priorto applying the metal alloy. The copper or copper alloy can be appliedby plating, cladding or other manner of bonding the copper or copperalloy to the metal strip. Generally the thickness of the copper orcopper alloy is about 2-100 microns, and typically about 2-50 microns.

Another additional or alternative pretreatment process is the preheatingof the metal strip prior to coating the metal strip with the corrosionresistant metal alloy. Metal strip that has a thickness of less thanabout 762 microns is typically not pre-heated. Thicker metal strip canbe preheated to assist in the formation of the heat createdintermetallic layer. A thin metal strip generally does not need to bepreheated since the surface of the thin strip quickly heats to thetemperature of the molten metal alloy. As the surface of the metal stripapproaches the temperature of the molten metal alloy, an intermetalliclayer begins to form between the surface of the metal strip and themetal alloy coating. Metal strip having a thickness of up to about 5080microns is classified as thin metal strip. However, thin metal strip canbe preheated and such preheated strip can result in the quickerformation of an intermetallic layer. Metal strip having a thickness overabout 5080 microns is classified as a thick metal strip. Thick metalstrip is typically preheated prior to coating with the metal alloy. Thesurface of a thick metal strip takes a longer time to approach thetemperature of the molten metal alloy due to the larger heat sink of thethicker metal strip. Preheating the thick metal strip facilitates in thesurface of the metal strip reaching or approaching the moltentemperature of the metal alloy during the coating process so that adesired heat created intermetallic layer is formed. Metal strip 12 canbe preheated in any number of ways, such as but not limited to,convection or induction heating, flames, lasers, and the like. When aheat created intermetallic layer is not to be formed, the meal strip istypically not pre-heated.

Although FIGS. 1A-1B illustrate metal strip 12 being pretreated by thepretreatment processes of abrasion, pickling and rinsing, chemicalactivation, exposure to low oxygen environment, and the flux solution,the use of all these pretreatment process on all types of metal strip isnot always required. When the metal strip has a clean surface and/orlittle or no oxide formation on the metal strip surface, thepretreatment process can be eliminated or only a select number ofpretreatment processes can be used prior to coating the metal strip withthe corrosion resistant metal alloy.

Referring to FIG. 1B, metal strip 12, after exiting flux box 72, entersmolten corrosion resistant metal alloy 76. Melting pot 70 is typicallyheated by heating jets, coils, rods, heat exchangers, etc. In onenon-limiting arrangement, melting pot 70 is heated by four heating jets71 directed at the outside sides of melting pot 70 as shown in FIG. 11.The heating jets are typically gas jets. Melting pot 70 is maintained ata temperature of at least several degrees Celsius above the meltingpoint of corrosion resistant metal alloy 76 to inhibit or preventsolidification of metal alloy 76 as metal strip 12 enters into andpasses through melting pot 70. Tin melts at about 232° C. (450° F.).Zinc melts at about 419.6° C. (787° F.). When additives and/orimpurities are included in the tin alloy or tin and zinc alloy, themelting point of metal alloy 76 will be altered. The composition and/orthickness of melting pot 70 is selected to accommodate the various metalalloy melting temperatures. The temperature of the molten metal alloycan be up to or more than 38° C. cooler at the top of the melting potthan at the bottom of the melting pot. Typically, the tin alloy or tinand zinc alloy is maintained at least about 2-30° C. above the meltingpoint of the metal alloy at the top of the melting pot. The temperatureof the metal alloy in the melting pot is selected to accommodate theinclusion of additives and/or impurities in metal alloy 76. Generally,the temperature of the molten metal alloy in the melting pot is about231-538° C. For high melting point metal alloys, additional heating jetsor other additional heating devices can be used to heat the metal alloyin the melting pot to the desired temperature.

The molten metal alloy in the melting pot is generally formed by addingingots of tin for a tin alloy coating and ingots of tin and ingots ofzinc for a tin and zinc alloy coating into the melting pot wherein theingots are melted and mixed. The ingots may contain some additionalelements which function as additives or impurities in the tin alloy ortin and zinc alloy. The amount of impurities in the metal alloy aregenerally controlled so as to reduce the adverse affects of suchimpurities.

As shown in FIG. 1B, melting pot 70 is divided into two chambers bybarrier 80. Barrier 80 is designed to inhibit or prevent protectivematerial 78, such as palm oil, from spreading over the complete topsurface of molten corrosion resistant metal alloy 76 in melting pot 70.As can be appreciated, barrier 80 can be eliminated. When the protectivematerial is palm oil, the melting point of the metal alloy should bebelow the 343° C. so as to not degrade the palm oil. For metal alloyshaving higher melting point temperatures, special oils, fluxes, or othermaterials and/or special cooling procedures are employed when aprotective material is used. Protective material 78 has a specificgravity which enables the protective material to at least partiallyfloat on the surface of molten alloy 76. The protective materialinhibits or prevents the surface of molten metal alloy from solidifyingby insulating the surface from the atmosphere, inhibits or prevents thesurface of molten metal alloy from oxidizing, and/or aids in theproperly distribution the metal alloy on the surface of metal strip 12upon exiting the molten metal alloy.

Melting pot 70 is generally about 10-100 ft. in length so as to providean adequate residence time for the metal strip in the molten metal alloyas the metal strip moves through the molten metal alloy 76 in themelting pot. Longer melting pot lengths can be employed for fast movingmetal strip. The residence time of the metal strip in the molten metalalloy is sufficiently long enough to form the desired thickness of heatcreated intermetallic layer 140 and the desired thickness of the metalalloy. The residence time of metal strip 12 in melting pot 70 isgenerally at least about 5 seconds and less than about 10 minutes,typically less than about 2-10 minutes, more typically less than aboutone minute, still more typically about 5-30 seconds, and even moretypically about 10-30 seconds. When the metal strip is coated with themetal alloy by a continuous immersion process, the metal strip istypically moved through the molten tin alloy in the melting pot in acurvilinear path; however, other paths can be used. When the metal stripuses a curvilinear path, the metal strip requires fewer, if any, guiderolls (driving rollers), especially when the metal strip is made of amore malleable material such as, but not limited to, aluminum or copper.The curvilinear path of the metal strip allows the metal strip to atleast partially dictate its path in the molten metal alloy. The coatingthickness of the metal alloy onto the metal strip is generally afunction of the time the metal strip is resident or immersed in themolten tin alloy. The coating thickness typically increases the longerthe metal strip is maintained in the molten metal alloy. In a continuousimmersion coating process, the resident time of the surfaces of themetal strip in the molten metal alloy is substantially the same. Theuniformity of residence time in the molten metal alloy results in a moreuniform coating thicknesses on the surface of the metal strip andsubstantially uniform growth of the heat created intermetallic layer.The metal strip is typically maintained at a constant speed through themolten metal alloy to create a more smooth coated surface. As the metalstrip passes through the molten metal alloy at a substantially constantspeed, the molten metal alloy about the metal strip adheres to themoving metal strip and shears a portion of the coating from the movingmetal strip. This shearing effect results from the viscosity of themolten metal alloy and the speed at which the metal strip is movingthrough the molten metal alloy. For a given speed and molten metal alloyviscosity, a constant shearing effect is applied to the surface of themoving metal strip thereby smoothing the coated surface and facilitatingin the formation of a substantially constant coating thickness. By usinga continuous coating process to coat the metal strip with a metal alloy,a uniform of coating (weight and thickness) is obtained, havingexcellent surface appearance, smoothness, texture control and asubstantially uniform heat created intermetallic layer.

During the coating of the metal strip with molten metal alloy, a heatcreated intermetallic layer 140 formed between the metal alloy coatinglayer 142 and metal strip 12 as shown in FIG. 12. The heat createdintermetallic layer includes elements of the corrosion resistant metalalloy molecularly intertwined with elements on the surface of metalstrip 12. This molecular intertwining occurs when the temperature of thesurface of the metal strip approaches the temperature of the moltencorrosion resistant metal alloy. The migration of the corrosionresistant metal atoms into the surface layer of strip 12 results in theformation of heat created intermetallic layer 140. A copper strip coatedwith a tin and zinc alloy or another metal that was coated with copperan then coated with a tin and zinc alloy would form an intermetalliclayer that includes at least copper and zinc. Intermetallic layer 140can include a number of elements such as, but is not limited to,antimony, aluminum, arsenic, bismuth, cadmium, chromium, copper,hydrogen, iron, lead, magnesium, manganese, nickel, nitrogen, oxygen,silicon, silver, sulfur, tellurium, tin, titanium, zinc and/or smallamounts of other elements or compounds depending on the composition ofthe metal strip, the corrosion resistant alloy, and the intermediatebarrier metal layer (if used). Heat created intermetallic layer 140 canbe thought of as a transition layer between metal strip 12 and corrosionresistant alloy coating 142. Heat created intermetallic layer 140 isbelieved to be at least partially responsible for the strong bond formedbetween corrosion resistant metal alloy layer 142 and metal strip 12.The heat created intermetallic layer also typically functions as acorrosion-resistant layer. Typically, the thickness of the heat createdintermetallic layer is at least about 0.1 micron, and typically about1-50 microns; however, thicker heat created intermetallic layers can beformed. The time needed to form the heat created intermetallic layer istypically less than about three minutes and generally less than aboutone minute; however, longer times can be used.

As shown in FIGS. 1B and 6, metal strip 12 passes between at least oneset of coating rollers 82 upon exiting the molten metal alloy in meltingpot 70. As best shown in FIG. 6, the coating rollers are partiallyimmersed in protective material 78. As can be appreciated, the coatingrollers can be completely immersed in the protective material orpositioned above the protective material. Coating rollers 82 are spacedapart a sufficient distance so that the coated metal strip can passbetween the coating rollers. The coating rollers 82 are designed tomaintain a desired coating thickness of the metal alloy on the metalstrip, remove excess metal alloy 76 from the metal strip, and/or coatany non-coated regions on the surface of the metal strip. The coatingthickness of the metal alloy is generally selected to ensure thatlittle, if any, uncoated regions exist on the surface of the metalstrip. Typically, the average thickness of the metal alloy on thesurface of metal strip 12 is at least about 1 micron, and generallyabout 7 to 2550 microns. The coating thickness is typically selected toensure the coated metal alloy has few, if any, pin holes, and/or doesnot shear when formed into various products. The thickness of the metalalloy is typically selected depending on the environment in which thecoated metal strip is to be used. A metal alloy coating thickness ofabout 25-51 microns generally forms a coating that has few pin holes,provides greater elongation characteristics of the coated metal strip,and/or significantly reduces the corrosion of the metal strip invirtually all types of environments. Metal alloy coating thicknessesgreater than about 51 microns are typically used in harsh environmentsto provide added corrosion protection.

Referring again to FIGS. 1B and 6, a metal spray process is shownwherein metal coating jets or spray jets 84 inject molten metal alloy 76on the surface of coating rollers 82. As can be appreciated, metalcoating jets 84 can be used to exclusively coat the metal strip, or beused in conjunction with a melting pot, coating rollers and/or othercoating process to apply metal alloy onto the surface of metal strip 12.As shown in FIG. 6, molten metal alloy is spray jetted from metalcoating jets 84 onto coating rollers 82 is then pressed against metalstrip 12 by coating rollers 82 as the metal strip 12 moves between thecoating rollers thereby filling in most, if not all, uncoated surfaceareas on metal strip 12 which were not coated as the metal strip passedthrough the molten alloy in melting pot 70. The motel metal alloy thatis supplied to the metal spray jets is at least partially taken from themelting pot 70 and pumped by pump P through a pipe and to the metalspray jets. As can be appreciated, the metal spray process and/or thecoating rollers can be used independently of the melting pot and/or bethe sole coating process used to coat the metal alloy onto the metalstrip.

Referring now to FIG. 7, an air-knife 100 can be used to direct a highvelocity gas toward metal alloy coating 76 on metal strip 12 as themetal strip exits melting pot 70. The air knife includes at least oneblast nozzle 104 that direct a high velocity gas onto the surface of themetal alloy on the metal strip. Typically, the air knife includes atleast two blast nozzles 104 which are mutually opposed from each otherand are disposed over melting pot 70. The blast nozzles direct highvelocity gas 105 toward metal strip 12 and toward the surface of meltingpot 70 as the metal strip moves by or between the blast nozzles.Generally, the blast nozzles are adjustable so as to direct the highvelocity gas at various angles on to the surface of the metal strip. Thehigh velocity gas removes surplus molten metal alloy coating 102 fromthe metal strip, smears the molten alloy on metal strip 12 to coveruncoated regions on the metal strip, reduces the thickness of the metalalloy coating on the metal strip, reduces lumps or ribs in the metalalloy coating, cools the metal alloy coating, and/or hardens the metalalloy coating. The high velocity gas is typically an inert gas so as notto oxidize the molten metal alloy. Use of an inert gas also reducesdross formation on the metal alloy coating and/or acts as a protectivebarrier to the atmosphere which causes viscous oxides to form on thesurface of the molten metal alloy in melting pot 70. When inert gas isused, the use of a protective material on the surface of the melting potcan be eliminated. Generally, the inert gas is, but is not limited to,nitrogen or an inert gas that is heavier than air (i.e. has a higherdensity than air). The blast nozzles are typically enclosed in a boxshaped sleeve which accumulates at least a portion of the gas after thegas is directed toward the metal strip. The accumulated gas can then berecirculated back through the blast nozzles. When an air-knife is usedto control the thickness and/or quality of the metal alloy coating, theair-knife is generally used as a substitute for or used in conjunctionwith coating rollers 82. As can be appreciated, the air-knife processcan be used after the metal strip is coated by one or more coatingrollers and/or by a metal spray jet.

Referring now to FIG. 3, an alternative process for coating metal strip12 with a corrosion resistant metal alloy is illustrated. FIG. 3 waspreviously referred to as illustrating a plating process for applying aplated intermediate metal barrier. FIG. 3 is now referenced as alsoillustrating the coating of a metal strip with a corrosion resistantmetal alloy by an electroplating process. This coating process for themetal alloy is a non-hot-dip process in that a heat createdintermetallic layer is not formed between the metal strip and metalalloy coating. Metal strip 12 is directed into electrolytic tank 44 andsubmerged in electrolyte 46. Metal strip 12 can be directed intoelectrolytic tank 44 immediately after being unrolled from metal roll10; after being pretreated by one or more pretreatment processes; and/orafter being coated with metal alloy by immersion, spray metal coating,and/or roller coating. As metal strip 12 passes through electrolytictank 44, an electrical current is directed into electrolyte 46 byelectrodes 48. The current through electrodes 48 is supplied by powersource 49. The plating of the metal alloy onto the surface of the metalstrip is typically effectuated by conventional electroplating processes.The metal alloy can be plated onto the surface of metal strip 12 by oneor more plating operations. After the metal strip is plated with themetal alloy, the metal strip is moved out of electrolytic tank 44. Theaverage thickness of the plated corrosion resistant alloy is generallyat least about 1 micron, and typically less than about 200 microns.Coating thickness of 2-77 microns, and 10-77 microns are typical coatingthicknesses. After the metal strip exits electrolytic tank 44, thecoated metal strip can be further treated by rinsing, heating, coatingwith a metal alloy by a hot-dip process, and/or one or more posttreatment processes.

When a heat created intermetallic layer is to be formed between themetal strip and the plated metal alloy coating, the plated metal alloycoating is heated. FIG. 4 illustrates one heating process used to form aheat created intermetallic layer between the metal strip and the platedmetal alloy coating. Coated metal strip is continuously moved betweentwo heaters 58. Heaters 58 cause the plated corrosion resistant metalalloy to soften and/or become molten. This process of heating the platedmetal alloy is referred to as flow heating and constitutes another typeof hot-dip process. During the flow heating process, a heat createdintermetallic layer is formed between the metal strip and metal alloycoating. The plated metal alloy is subjected to heat for a sufficienttime period to form a heat created intermetallic layer having a desiredthickness. As can be appreciated, the heating process can occur insingle or in multiple stage processes. Furthermore, the heating processcan be designed to heat a part of or the complete coated region on themetal strip. After the metal strip is flow heated, the metal alloycoating can be further modified by a process such as, but not limitedto, controlling the coating thicknesses by an air-knife process and/or acoating roller process, and/or coating additional layers of metal alloyby additional coating process such as, but not limited to, a platingprocess, a metal spray process, a coating roller process, and/or animmersion process.

After metal strip 12 is coated with a corrosion resistant alloy, thecoated metal strip is cooled and/or rinsed. A coated metal strip that isplated as it moves through an electrolyte solution is typically rinsedoff to remove electrolyte solution remaining on the surface of thecoated metal strip. A coated metal strip that is coated by a hot-dipprocess is typically cooled to reduce the temperature and/or harden themetal alloy coating. Referring to FIGS. 1B, 8 and 10, the coated metalstrip can be cooled by applying a cooling fluid 93 on the coated metalstrip by at least one spray jet 92. Typically, the cooling fluid is, butnot limited to, water maintained at about ambient temperature. As can beappreciated, multiple temperature cooling fluids can be applied to thecoated metal strip. For example, the coated metal strip can be firstcooled by steam and then by water near ambient temperature. The velocityof the cooling fluid can be varied to obtain the desired cooling rateand/or rinsing effect of the corrosion resistant metal alloy. Asillustrated in FIGS. 1B and 10, metal strip 12 is guided by camel-backguides 90 during the cooling process. Camel-back guide 90 is designedsuch that it has two receding edges 91 formed by conical surfaces whichcontact only the edges of metal strip 12 so as to minimize the removalof the metal alloy coating from metal strip 12. Alternatively or inaddition to the spray cooling process, the coated metal strip can becooled in a cooling tank 94 as illustrated in FIG. 5. The coated metalstrip is partially or fully immersed in the cooling fluid 96 to cooland/or rinse the coated metal strip. Typically, the cooling fluid is,but not limited to, water maintained at about ambient temperature. Thecooling fluid is also typically agitated to increase the rate of coolingof the metal alloy coating, and/or maintain a relatively uniform coolingfluid temperature. The temperature of the cooling water is typicallymaintained at proper cooling temperatures by recycling the water throughheat exchangers and/or replenishing the cooling fluid. The cooling watermay not be deoxygenated prior to cooling the coated metal strip coatingso as to slightly discolor the metal alloy coating and/or reduce thereflectiveness of the metal alloy coating. Immersion of the coated metalstrip in cooling fluid 96 generally results in a faster cooling ratethan cooling by spray jets 92. Rapid cooling of the corrosion resistantmetal alloy generally produces a metal alloy coating having fine grainsize with increased grain density. Typically, the metal alloy is cooledat a rate such that there are no more than about 40 zinc crystals in themetal alloy have a maximum dimension of over about 400 μm within a 0.25mm² region of the metal alloy. In addition, cooling of the metal alloycoating in water results in some oxidation of the metal alloy coatingsurface which can result in a less-reflective surface, if such a surfaceis desired. The cooling period for cooling coated metal strip 12 bycooling jets 92 or by immersion in cooling tank 94 is generally lessthan about 10 minutes, typically less than about 5 minutes, moretypically less than about 2 minutes, and even more typically about 10-30seconds.

After the coated metal strip is cooled, the coated metal strip may berolled into a metal roll, partially or totally formed into variousshapes (i.e. roofing materials, building materials, household parts,automotive parts, etc.), cut into sheets, or processed by a post coatingprocess (e.g oxidation of the coating to partially or fully expose theheat created intermetallic layer, passifying the heat createdintermetallic layer, etc.).

As illustrated in FIG. 15, the metal strip is unrolled and immediatelydirected into a molten bath of metal alloy without any priorpretreatment processes. Copper metal strip is typically unrolled andimmediately coated with a molten metal alloy as illustrated in FIG. 15.Upon exiting the molten metal bath, the metal strip passes betweencoating rollers and is then subjected to an air-knife process to controlthe coating thickness and reduce the uncoated regions on the metal stripsurface. The air-knife also cools and hardens the metal alloy coating sothat the coated metal strip can be immediately rolled into a metal roll150.

As illustrated in FIG. 2, the coated metal strip can be furtherprocessed prior to being rolled into a metal roll 150 or cut in tosheets 130. This further processing includes, but is not limited to,leveling, shearing, oxidizing the coated corrosion resistant alloy,passifying the metal alloy and/or heat created intermetallic layer,applying weathering agents, applying paints, sealants etc. As shown inFIG. 2, the coated metal strip is subjected to a leveler 100. Leveler100 includes several rollers 102 which produce a uniform and smoothcorrosion resistant alloy coating 142 on metal strip 12. Typically thesurface coarseness Ra of the metal alloy after passing through theleveler is less than about 5 μm. After metal strip 12 exits leveler 100,metal strip 12 is illustrated as being cut into sheets 130 by shear 111.The coated metal sheets or strip can be further processed by applying apaint, sealant or weathering agent on the surface of the coated metalsheets or strip. The paint, sealant or weathering agent 112 can beapplied to a portion or the full surface of the coated metal alloy. Thepaint, sealant or weathering agent can be applied by coaters 114 and/orby sprayers 116. A reservoir 110 holds the paint, sealant or weatheringagent for coaters 114 and/or sprayers 116. After the paint, sealant orweathering agent is applied, it can be dried by heat lamp 120 and/or bya dryer 122.

When a weathering agent is applied to the coated metal strip, theweathering agent is used to accelerate the patina formation on the metalalloy coating. This process is generally used to discolor the metalalloy and/or reduce the reflectiveness of the metal alloy. The naturalweathering of the metal alloy can take, in some instances, over tenyears to weather to the desired degree. The weathering agent isformulated to reduce the time period of weathering. In one non-limitingformulation, the weathering agent is typically a petroleum basedproduct. Generally, the petroleum based weathering agent is an asphaltbased paint containing a suspension of free carbon and a thinner. Whenthis formulation is used, a thin film or coating of weathering agent isapplied to the surface of the metal alloy and the ultraviolet light fromthe atmosphere facilitates in accelerating the weathering of the metalalloy. Generally, the thin layer of weathering agent is asemi-transparent or translucent coating and at least partially allowsthe metal alloy to be exposed to oxygen, moisture and to the sun'sradiation. The weathering agent can include, but is not limited to,asphalt, titanium dioxide, inert silicates and low clay, carbon black(lampblack) or other free carbon and an anti-settling agent. The asphaltmakeup of the weathering agent is typically about 60% to 80% by weightof the weathering agent, typically about 64% to 78% by weight of theweathering agent, and more typically about 68% by weight of theweathering agent. The amount of titanium oxide in the weathering agentis about 1% to 25% by weight of the weathering agent, and typicallyabout 19% by weight of the weathering agent. Typically, over 50% of thetitanium oxide is anatase grade. When carbon black is added to theweathering agent, the carbon black is present in an amount of up toabout 2% by weight of the weathering agent, typically about 0.5 to 1% byweight of the weathering agent, and more typically about 0.7% by weightof the weathering agent. The inert silicates and/or low clay, such as,but not limited to calcium borosilicate, when added to the weatheringagent, is present in an amount of about 8-11% by weight of theweathering agent. The antisettling agent, when added to the weatheringagent, is present in an amount of about 0.4-0.7% by weight of theweathering agent, and typically about 0.5% by weight of the weatheringagent. One specific formulation of the weathering agent includes about60-80 weight percent asphalt, about 1-25 weight percent titanium oxide,about 8-11 weight percent inert silicates and clay, about 0.5-2 weightpercent carbon black, about 0.4-0.7 weight percent anti-settling agent,and solvent. Another specific non-limiting formulation of the weatheringagent includes 65-75 weight percent gilsonite, 15-20 weight percenttitanium oxide, 8-11 weight percent calcium borosilicate, 0.5-1 weightpercent carbon black, 0.4-0.6 weight percent anti-settling agent, andsolvent. Still another specific non-limiting formulation of theweathering agent includes 64-78 weight percent gilsonite, 11.68-20.5weight percent titanium oxide, 8.4-10.3 weight percent inert silicatesand clay, 0.63-0.77 weight percent carbon black, 0.4-0.52 weight percentanti-settling agent, and solvent. Yet another non-limiting specificformulation of the weathering agent includes 70.86 weight percentgilsonite, 18.65 weight percent titanium oxide, 9.32 weight percentcalcium borosilicate, 0.7 weight percent carbon black, 0.47 weightpercent anti-settling agent, and solvent. A solvent such as, but notlimited to, naphthalene and/or paint thinners, is used to thin theweathering agent so that a thin, translucent or semi-translucent filmcan be formed on the surface of the metal alloy. The thickness of theweather agent layer is generally less than about 123 mils, moretypically about 6-123 microns, even more typically up to about 50microns, yet even more typically up to about 25 microns, and still moretypically about 12-25 microns. The color of the weathering agent istypically a dull, lackluster color which has low reflective properties.As a result, the weathering agent accelerates the patina formation onthe metal alloy coating and reduces the reflective properties of thenewly applied or formed metal alloy. Another type of weathering agentwhich can be used is disclosed in U.S. Pat. No. 5,296,300, which isincorporated herein.

When a sealant is applied to the coated metal strip, the sealant istypically used to provide additional protection to the coated metalalloy and/or coated base metal. The protective layer can be chromatefilm, phosphate coating, and/or an organic-inorganic composite film. Theprotective coating is typically formulated to have a high compatibilitywith the metal alloy layer. The protective layer is also typicallyformulated to cover imperfections in the metal alloy coating, and/or toprovided additional corrosion resistance to the metal alloy coating. Theprotective coating typically is has a thickness of about 1-150 microns,and typically about 1-50 microns. The protective layer is typicallydried by air drying and/or by heating lamps.

Metal strip 12 can be oxidized to partially or fully expose the heatcreated intermetallic layer prior to or subsequent to the coated metalstrip being rolled into a metal roll, cut into sheets of strip, and/orformed into various shapes. To expose the heat created intermetalliclayer, the coated metal alloy can be ground off and/or chemicallyremoved. Typically the metal alloy coating is chemically removed by anoxidizing solution. As shown in FIG. 13, coated metal strip is immersedin oxidizing solution 133 in oxidizing tank 132. The oxidizing solutionis formulated to at least partially removes the metal alloy coating frommetal strip 12 thereby at least partially exposing heat createdintermetallic layer 140. The intermetallic layer has been found in manyenvironments to be an excellent corrosion resistant layer. Oxidationtank 132 is of sufficient length and depth to facilitate completeimmersion of metal strip 12 in oxidation solution 133 and to maintainthe metal strip in contact with the oxidation solution for a sufficientperiod of time. Typically, oxidation tank 132 is at least about 20 feetin length. As can be appreciated, the oxidation tank can be longer orshorter depending on the speed of the metal strip. Furthermore, theoxidation tank can be designed so that only a portion of the surface ofmetal strip 12 contacts the oxidation solution. The oxidation tanktypically includes one or more agitators, not shown. The agitators aredesigned to agitate oxidation solution 133 to maintain a uniformsolution concentration, maintain a uniform solution temperature, and/orbreak up gas pockets which form on the surface of metal strip 12. Theagitators typically include an abrasive material which can both agitatethe oxidation solution and facilitate in the removal of the metal alloyon the surface of metal strip 12 when in contact with the surface of themetal strip. The agitators are typically made of a material which doesnot react with oxidation solution 133 and resists undue wear when incontact with the metal strip surface. The oxidizing solution typicallyincludes an acid such as, but not limited to, nitric acid. When nitricacid is included in the oxidation solution, the nitric acidconcentration is generally about 5%-60% by volume and typically about10-25% by volume, more typically about 25% by volume, and even moretypically about 20% by volume. Copper sulfate is generally added to theacid in the oxidizing solution to improve the oxidation of the metalalloy coating. Copper sulfate, when present, is generally added in aconcentration of less than about 10% by volume, typically about 0.5-2%by volume, and more typically about 1% by volume. The temperature of theoxidizing solution is maintained at a temperature that providessufficient activity of the oxidizing solution. Generally, thetemperature is maintained between about 20-80° C., typically about30-80° C., more typically about 40-60° C., and even more typically about50° C.; however, other temperatures can be used. By increasing theconcentration and/or temperature of the oxidation solution, the timeneeded to at least partially remove the metal alloy coating 76 isshortened. Metal strip 12 is generally not exposed to the oxidationsolution for more than about 20 minutes, typically less than about tenminutes, more typically less than about two minutes, still moretypically about 0.08-1.5 minutes, and even more typically about 0.33minutes; however, longer oxidation times can be used depending on thetype of oxidation solution, concentration and temperature of theoxidation solution, type of metal alloy, and/or thickness of the metalalloy. The exposed heat created intermetallic layer is typically has adark grey, non-reflective surface. As can be appreciated, the oxidationsolution can be applied to the coated metal strip after or just prior tothe metal strip being formed and/or installed. In this instance, theoxidizing solution can be swabbed or sprayed onto the surface of thecoated metal strip.

Once the desired amount of metal alloy coating is removed, the exposedheat created intermetallic layer is typically passivated to enhance thecorrosion-resistance of the intermetallic layer. The intermetallic layeris generally passivated by a passivating solution. One type ofpassivating solution includes a nitrogen containing solution and/or achromium solution such as, but not limited to, nitric acid and/orchromate acid. The passivation solution can be the same as or differentfrom the oxidizing solution. When chromate acid is included in thepassivation solution, the concentration of chromate acid is generallyabout 0.5-5 g/liter. Phosphate can be added to the passivation solutionto enhance the passivation of the metal alloy. When the passivationsolution and the oxidizing solution are the same, the removal of metalalloy coating and passivation of the heat created intermetallic layercan both be accomplished in a single tank. In a single tank arrangement,the passivation solution and the oxidizing solution are formulated suchthat when the heat created intermetallic layer is exposed and thenpassified, the passivated layer is not removed or very slowly removed bythe passivation solution and the oxidizing solution, thus making theoxidation and passivation process autocatalytic or semi-autocatalytic.As illustrated in FIG. 13, metal strip 13 is directed into a passivationtank 135 after being oxidized in oxidation tank 132. The passivationtank 132 typically includes an agitator to prevent or reduce stagnationand/or vast concentration differences of the passivation solution in thetank, prevent or reduce gas bubbles from forming on the surface of metalstrip 12, and/or maintain a substantially uniform temperature for thepassivation solution. The temperature of the passivation solution ismaintained at a temperature that provides sufficient activity of thepassivation solution. Generally, the temperature of the passivationsolution is maintained between about 15-80° C., typically about 40-60°C. By increasing the concentration and/or temperature of the passivationsolution, the time needed to at least partially passivate the exposedheat created intermetallic layer is shortened. The amount of time topassivate the heat created intermetallic layer is generally less thanabout ten minutes, and typically about 0.02-1.5 minutes; however, longertimes can be used.

Referring now to FIG. 14, passivation layer 146 is a very thin layer.Generally, the thickness of the passivation layer is less than about 13microns, typically less than about 3 microns, and more typically up toabout 1.5 microns. The passivation layer facilitates in inhibiting orpreventing oxidation (i.e. white rust) of the outer metal layer. Thepassivation layer 146 can significantly enhance the corrosion-resistanceof the intermetallic layer 142. Although it is not entirely known howpassivation layer 148 exhibits increased corrosion resistance, it isbelieved that a unique covalently bonded system is formed when theintermetallic layer is passified. When the intermetallic layer 142 ispassified with passivation solution 162, a chemical reaction is believedto occur to modify the atomic structure of passivation layer 146. Otherelements such as, but not limited to, nitrogen, hydrogen, oxygen mayalso be present in passivation layer 146 to enhance the stability ofpassivation layer 146. The special formulation of the intermetalliclayer 142 in combination with the passivation layer 146 provides forsuperior corrosion resistance for metal strip 12. Passivation layer 146is typically malleable and generally does not crack when formed intovarious shapes. Passivation layer 146 is generally a grey, earth tonecolor non-reflective surface. Passivation layer 146 displays increasedcorrosion resistance, abrasion resistance, and/or increased hardness ascompared to the heat created intermetallic layer. Heat createdintermetallic layer 142 and passivation layer 146 are generallyresistant to scratching thereby improving the visual quality of metalstrip 12 and/or enhancing the damage resistance of metal strip 12. Therelative nonexistence of lead in intermetallic layer 142 and passivatedlayer, especially when low lead metal alloys are used, makes thepassivated metal strip a superior substitute to terne coated materials.Not only is the corrosion resistance of the intermetallic layer andpassivated layer greater than terne coatings in many differentenvironments, the intermetallic layer and the passivated layer containlittle, if any, lead thereby alleviating any concerns associated withthe use of lead materials.

After metal strip 12 is oxidized and/or passified, metal strip 12 istypically rinsed to remove any oxidation solution and/or passivationsolution remaining of the metal strip. The rinse process can beperformed by liquid spray jets and/or immersion of the metal strip in atank that contains a rinse solution. Typically, the rinse liquid isabout ambient temperature. The rinse tank, when used, typically includesan agitator to assist in the removal of the oxidizing solution and/orpassivation solution from metal strip 12. Once the rinse process iscomplete, the metal strip is rolled into strip roll 150, cut into sheets130, preformed to various articles, and painted or sealed.

Referring now to FIGS. 16-18, a fuel tank is formed from coated metalstrip 12. Fuel tank 160 is made up of two shell members 162 and 164. Ascan be appreciated, the fuel tank can be made of more or less members.The shell members are typically shaped in a die by placing the coatedmetal strip or a section thereof on a die and drawing the coated metalstrip over the die. As can be appreciated, the shell members can beformed by other process such as, but not limited to, Hot Metal GasForming processes, Hydraulic Metal Forming process, etc. The shells aretypically formed in a cylindrical shape and each have a peripheral edge166; however, other shapes can be formed. The two shells are joinedtogether at the respective peripheral edges to form an inner fuelreceiving chamber 168 wherein the fuel is stored within the tank. Fueltank 160 also contains a spout 170 which communicates with interiorchamber 168 of the fuel tank so that the fuel can be inserted into theinner chamber. Typically, the spout is inserted at the top portion ofshell 162 for easy insertion of the fuel into the tank; however, thespout can be located in other areas. Fuel tank 160 also contains a drainhole 172 which communicates with the interior of the fuel tank chamberand the fuel system of a motor of a vehicle, boat, airplane, etc.Typically, drain hole 172 is located at the top of the fuel tank onshell 162; however, the drain hole can be located in other areas. A fuelpump can be located in the inner chamber of the fuel tank to pump thefuel out of and/or into the inner chamber.

As illustrated in FIG. 18, shell members 162 and 164 are joined togetherby abutting and connecting together peripheral edges 166 of therespective shell members. Typically, the peripheral edges are connectedtogether a weld or solder 180; however, the peripheral edges can beconnected together by other or additional means. Spout 170 and drainhole 172 are also connected to the shell member typically by a weld orsolder; however, the spout and/or drain hole can be connected by otheror additional means. Generally, the weld or solder is essentiallylead-free so as not to add any lead to the fuel tank. Each shell memberincludes a corrosion resistant metal alloy coating 186 and an innercorrosion resistant metal alloy coating 188. Typically the thicknessesof the two coatings are the same. When the coated metal strip is drawnover the die, the corrosion resistant metal alloy coating 186,188becomes elongated about the peripheral edge corner 190. When corrosionresistant metal alloy coating is elongated, the corrosion resistantmetal alloy coating can reduce in thickness. If the corrosion resistantalloy coating is too thin, the alloy coating can tear or shear andexpose the unprotected surface of metal strip 12. Typically, the averagethickness of the corrosion resistant metal alloy coating is at leastabout 7 microns so that as the metal alloy coating can be elongated andshaped by the die with little, if any, incident of shearing and exposingthe surface of the base metal of the metal strip. Examples of fuel tanksthat can be used are disclosed in U.S. Pat. Nos. 5,827,618; 5,695,822;5,667,849; 5,616,424; 5,597,656; 5,491,036; 5,491,035; and 5,455,122,which are incorporated herein by reference.

Referring now to FIGS. 19-20, building materials such as roofing panelsare illustrated as being formed from the coated metal strip. Roofingpanels P are joined together by an elongated standing seam S. Roofingpanels P are typically formed on site or preformed in the shape ofelongated pans as shown in FIG. 19. Pans 200 and 202 are illustrated ashaving substantially similar features. Both pans have a right edgeportion 204 and a left edge portion 206. As shown in FIG. 20, pans 202and 204 are adjacently positioned together to define the elongateddirection D lying along base line X. A cleat 210 is used to form seal S.Nails 212 are typically used to maintain the pans on roof 220 while seamS is formed. In standing seam applications, the edges of the roofingmaterials are typically folded together and then soldered to form awater tight seal. The metal alloy coating inherently includes excellentsoldering characteristics. The metal alloy coating can be also welded orsoldered. Typical solders contain about 50% tin and about 50% lead;however, higher lead content solders can be used. The metal alloy hasthe added advantage of being solderable with low or no-lead solders. Theroofing materials can be used in mechanically joined roofing systems dueto the malleability of the metal alloy. Mechanically joined systems formwater tight seals by folding adjacent roof material edges together andsubsequently applying a compressive force to the seam which is typicallyin excess of about 1,000 psi. Under these high pressures, the metalalloy plastically deforms within the seam and produces a water tightseal. This type of roofing system is disclosed in U.S. Pat. Nos.4,934,120; 4,982,543; 4,987,716; 4,934,120; 5,001,881; 5,022,203;5,259,166; and 5,301,474, which are incorporated herein by reference.

Referring now to FIG. 21, a corrosion resistant metal alloy is formedinto a metal alloy strip 230 by a roll forming process. As can beappreciated, the metal alloy can alternatively be formed into a wire, atube, or molded or cast into other shapes. Ingots of tin or tin and zincare typically placed into the melting pot 240 wherein the tin or the tinand zinc ingots are melted. The molten metal alloy is maintained aboveits melting point in the melting pot. Other metals such as, but notlimited to, iron, nickel, aluminum, titanium, copper, manganese,bismuth, antimony can be added into the melting pot to alter thecomposition of the metal alloy, and/or can be included due to impuritiesin the tin and/or zinc ingots. The inclusion of these other metalstypically alters the melting point of the metal alloy. In order toaccommodate for the high melting temperature of the metal alloy, themelting pot is made of materials to withstand such temperatures. Oncethe metal alloy is properly mixed and melted in melting pot 240, themolten alloy is allowed to flow out of the bottom of the melting potthrough pot opening 242. The molten metal alloy 230 is then directedthrough one or more sets of rollers 260 until the desired thickness ofthe metal alloy sheet or strip is obtained. The process of roll formingmetal strip is well known in the art, thus further details as to theforming of the metal alloy strip 230 will not be discussed. Thethickness of the formed metal alloy strip 230 is typically less thanabout 5080 microns. Once metal alloy strip 230 has passed throughrollers 260, metal alloy strip 230 may be further processed, such as bya pretreatment processes, a coating process, and/or a post coatingprocess as discussed above. As shown in FIG. 21, metal alloy strip 230is directed into a passivation tank 270. Passivation tank 270 includes apassivation solution 272. The passivation solution is typically the samepassivation solution as described above. As the metal alloy strip isdirected into passivation tank 270, guide rollers 280 guide the metalalloy strip. The passivation solution reacts with the surface of themetal alloy strip to form a passivation layer which is highly corrosionresistant. The passivation solution also causes the surface of the metalstrip to change colors. The passivation tank generally includes anagitator to prevent or inhibit stagnation and/or vast concentrationdifferences of the passivation solution in the passivation tank. Aftermetal alloy strip 230 passes through the passivation tank, the metalalloy strip typically proceeds to a rinsing process, not shown, toremove passivation solution remaining on the metal alloy strip.Generally, the passivation solution is removed by passing the metalalloy strip through a rinse tank and/or by spraying the metal alloystrip with a rinse fluid. As shown in FIG. 21, after metal alloy stripis passivated, the strip is rolled into a roll 290 of metal alloy strip.As can be appreciated, the molten metal alloy can alternatively beformed into a wire or tube. Such wire or tube can be used for pipes,wire, cable, solder or welding wire. When the metal alloy is formed intoa solder or welding wire, the metal alloy is generally not passivated.The solder or welding wire has been found to form a strong bond with themetal materials and has excellent wetting properties to create a highquality bond. The solder also has good conductive properties so that itcan be used to form electrical connections. The types of base metalswhich can be soldered by the metal alloy include, but are not limitedto, carbon steel, stainless steel, copper, copper alloys, aluminum,aluminum alloys, nickel alloys, tin, titanium, titanium alloys.Materials coated with tin, tin alloys, zinc, zinc alloys, tin and zincalloys, lead, lead and tin alloys, and various other metals can also besoldered or welded by the metal alloy. The metal alloy strip can also beformed into roofing materials and/or gasoline tanks, as described above,or a variety of components.

The corrosion resistant metal alloy described above is a tin alloy or atin and zinc alloy. Both of these metal alloys exhibit excellent bondingand corrosion resistant properties when applied to a base metal by a hotdip process and/or by a plating process.

The tin alloy is formulated to include at least a majority of tin.Generally, the tin alloy includes at least about 75 weight percent tinand less than about 10 weight percent zinc, and typically at least about90 and less than about 10 weight percent zinc. In certain tin alloys,the tin content can at least about 95 weight percent tin, or at leastabout 98 weight percent tin, or at least about 99 weight percent tin.The high percentage of tin in the tin alloy is substantially differentfrom standard terne alloy formulations which contain about 80% lead and20% tin. The high concentration of tin in the tin alloy increases theuniformity and strength of the bond between the tin alloy and many typesof metal strip 12 as compared with standard terne alloy coatings. Thesuperior bonding characteristics of the tin alloy makes the tin alloycoating ideal for use with many different types of metal stripcompositions, and can be formed in a variety of simple and complexshapes. Industrial grade tin typically is used as the tin source for thetin alloy; however, other sources of the tin can be used. Industrialgrade tin typically contains trace amounts of impurities such as, butnot limited to, cobalt, nickel, silver and sulphur. It has been foundthat these elements in controlled amounts do not adversely affect thecorrosive resistive properties of the tin alloy. Indeed, elements suchas, but not limited to, nickel can enhance some properties of the tinalloy.

The tin and zinc alloy is a special combination of tin and zinc. The tinand zinc alloy is formulated to include at least about 9-10 weightpercent zinc and at least about 15 weight percent tin and the majorityweight percent of the tin and zinc alloy includes tin and zinc. It hasbeen found that the addition of zinc in the amount of at least about9-10 weight percent of the tin and zinc alloy produces a metal alloyhaving enhanced corrosion-resistance in various types of environments.The tin content of the tin and zinc alloy is generally about 15-90weight percent. The zinc content of the alloy is generally about 9 to10-85 weight percent. The tin plus zinc content of the tin and zincalloy typically constitutes at least a majority of the tin and zincalloy. Typically, tin plus zinc content of the tin and zinc alloyconstitutes at least about 75 weight percent tin and zinc, moretypically at least about 80 weight percent tin and zinc, even moretypically at least about 90 weight percent tin and zinc, still even moretypically at least about 95 weight percent tin and zinc, yet still evenmore typically at least about 98 weight percent tin and zinc, and yetstill even more typically at least about 99 weight percent tin and zinc.The tin and zinc formulation typically oxidizes to form a coloredcoating which closely resembles the popular grey, earth-tone color ofweathered terne. The use of large weight percentages of zinc in the tinand zinc alloy has been found to not cause the coating to become toorigid or too brittle. The tin and zinc alloy is formable thus can be, inmany instances, bent into simple or complex shapes without cracking orbreaking. The malleability of tin and zinc alloy is believed to be atpartially the result of the unique tin and zinc distributions within thetin and zinc alloy. The tin and zinc form a two phase matrix whereinzinc globules or crystals are at least partially surrounded by tin. Zincfacilitates in stabilizing the tin in the tin and zinc alloy so as toinhibit or prevent tin crystallization in the tin and zinc alloy. Whendetermining the composition of the tin and zinc alloy, the environmentthe coating is to be used in should be considered. In some situations, ahigher tin concentration may be beneficial to limit the amount of zincrich globules or crystals in the tin and zinc alloy. In otherenvironments, the reverse may be true.

The tin alloy or the tin and zinc alloy typically contains one or moreadditives without adversely affecting the tin alloy or the tin and zincalloy; however, the addition of additives is not required. The additivesare included and/or added to tin alloy or the tin and zinc alloy tomodify the mechanical properties of the metal alloy, thecorrosion-resistance of the metal alloy, the color of the corrosionresistant metal alloy, the stability of the metal alloy, and/or thecoating properties of the metal alloy. The additive(s) generallyconstitute less than about 25 weight percent of the metal alloy.Typically, the additive(s) constitute less than about 10 weight percentof the metal alloy. The content of the additives is controlled so thatthe additives properly mix with the metal alloy. The proper mixing ofthe additives in the metal alloy is of greater importance for a tin andzinc alloy wherein the tin and zinc form a special two phase matrix.Typically, the additives are added to a tin and zinc alloy in a mannerthat maintains the two phase matrix of the tin and zinc so as not toform a tin and zinc alloy having more than two phases or which disruptsthe tin and zinc matrix.

The tin alloy typically includes at least an effective amount of one ormore stabilizing additives to inhibit or prevent the tin fromcrystallizing. The tin and zinc alloy can also include stabilizingadditives; however, such additives can be eliminated since the zinc inthe tin and zinc alloy generally facilitates in stabilizing the tin toinhibit or prevent the tin from crystallizing. Tin can begin tocrystallize when the temperature drops below about 13° C.Crystallization of the tin in the alloy can weaken the bond between themetal strip and the metal alloy and can result in flaking of the metalalloy from the metal strip. The addition of small amounts of stabilizingmetals such as, but not limited to, antimony, bismuth, cadmium, copper,zinc and mixtures thereof prevent and/or inhibit the crystallization ofthe tin in the metal alloy. Only small amounts of one or more of thesemetals is needed to stabilize the tin in the metal alloy and inhibitand/or prevent the tin from crystallizing. Amounts of at least about0.001-0.01 weight percent of the metal alloy are generally sufficient toinhibit or prevent tin crystallization. Typically, the one or morestabilizing metals are included in an amount of at least about0.001-0.005 weight percent of the metal alloy to inhibit crystallizationof the tin.

The tin alloy or tin and zinc alloy can include other additives to alterand/or enhance one or more properties of the metal alloy. The metalalloy can include at least an effective amount of corrosion-resistantagent to enhance the corrosion-resistant properties of the metal alloy.The corrosion-resistant agent includes, but is not limited to, antimony,bismuth, cadmium, chromium, copper, lead, manganese, magnesium, nickel,titanium and/or zinc. The metal alloy can include at least an effectiveamount of coloring agent to alter the color of the metal alloy. Thecoloring agent includes, but is not limited to, cadmium, copper, iron,lead, silver and/or titanium. The metal alloy can include at least aneffective amount of reflective agent to positively alter thereflectiveness of said metal alloy. The reflective agent includes, butis not limited to, aluminum, cadmium, chromium, copper, silver and/ortitanium. A metal alloy which includes a sufficient amount of coloringagents and/or reflective agent may not be required to be weathered orweathered as long prior to use in certain applications. The metal alloycan include at least an effective amount of grain agent to positivelyalter the grain density of the metal alloy. The grain agent includes,but is not limited to, cadmium, manganese and/or titanium. The metalalloy can include at least an effective amount of mechanical agent topositively alter the mechanical properties of the metal alloy. Themechanical properties of the metal alloy include, but are not limitedto, the strength of the metal alloy, the hardness of the metal alloy,the pliability of the metal alloy, the elongation of the metal alloy,the tensile strength of the metal alloy, the elasticity of the metalalloy, the rigidity of the metal alloy, the conductivity of the metalalloy, the heat transfer properties of the metal alloy, etc. Themechanical agent includes, but is not limited to, aluminum, antimony,arsenic, bismuth, cadmium, chromium, copper, iron, lead, magnesium,manganese, nickel, silver, titanium, and/or zinc. The metal alloy caninclude at least an effective amount of deoxidizing agent to reduce theamount of oxidation of the metal alloy in a molten state. Thedeoxidizing agent includes, but is not limited to, aluminum, cadmium,magnesium, manganese and/or titanium. The metal alloy can include atleast an effective amount of bonding agent to enhance the bondingproperties of the metal alloy to the metal strip and/or intermediatebarrier metal layer. The bonding agent includes, but is not limited to,cadmium, lead, manganese, titanium and/or zinc.

Aluminum, if added to and/or included in the metal alloy, is generallypresent in amounts up to about 5 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the aluminum content of the metal alloy is a) upto about 2 weight percent of the metal alloy, b) up to about 1 weightpercent of the metal alloy, c) up to about 0.75 weight percent of themetal alloy, d) up to about 0.5 weight percent of the metal alloy, f) upto about 0.4 weight percent of the metal alloy, g) up to about 0.3weight percent of the metal alloy, h) up to about 0.25 weight percent ofthe metal alloy, i) at least about 0.05 weight percent of the metalalloy, j) about 0.1-1 weight percent of the metal alloy, k) about0.1-0.5 weight percent of the metal alloy, l) about 0.1-0.3 weightpercent of the metal alloy, m) about 0.01-1 weight percent of the metalalloy, n) about 0.01-0.5 weight percent of the metal alloy, o) about0.01-0.3 weight percent of the metal alloy, p) about 0.01-0.1 weightpercent of the metal alloy, q) about 0.0005-0.75 weight percent of themetal alloy, r) about 0.001-0.5 weight percent of the metal alloy, s)about 0.001-0.4 weight percent of the metal alloy, t) about 0.002-0.4weight percent of the metal alloy, u) about 0.001-0.4 weight percent ofthe metal alloy, v) about 0.001-0.01 weight percent of the metal alloy,and w) about 0.0001-0.005 weight percent of the metal alloy, x) about0.001-0.005 weight percent of the metal alloy, and y) less than about0.001 weight percent of the metal alloy. When aluminum is added to themetal alloy, the aluminum is typically added in the form of an alloysuch as, but not limited to, Al—Cu—Mg alloy.

Antimony, if added to and/or included in the alloy, is generally presentin amounts up to about 7.5 weight percent of the metal alloy; however,higher weight percentages can be used. In several aspects of the presentinvention, the antimony content of the metal alloy is a) up to about 5.5weight percent of the metal alloy, b) up to about 2.5 weight percent ofthe metal alloy, c) up to about 2 weight percent of the metal alloy, d)up to about 1 weight percent of the metal alloy, e) up to about 0.75weight percent of the metal alloy, f) up to about 0.5 weight percent ofthe metal alloy, g) about 0.001-1 weight percent of the metal alloy, h)about 0.005-0.8 weight percent of the metal alloy, i) about 0.01-0.8weight percent of the metal alloy, j) about 0.01-0.5 weight percent ofthe metal alloy, and k) about 0.05-0.5 weight percent of the metalalloy.

Bismuth, if added to and/or included in the metal alloy, is generallypresent in amounts up to about 1.7 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the bismuth content of the metal alloy is a) upto about 1 weight percent of the metal alloy b) up to about 0.5 weightpercent of the metal alloy, c) up to about 0.01 weight percent of themetal alloy, d) about 0.0001-0.5 weight percent of the metal alloy, e)about 0.05-0.5 weight percent of the metal alloy, f) about 0.0001-0.2weight percent of the metal alloy, g) about 0.002-0.1 weight percent ofthe metal alloy, and h) about 0.001-0.01 weight percent of the metalalloy.

Cadmium, if added and/or included in the metal alloy, is present inamounts of up to about 0.5 weight percent of the metal alloy; however,higher weight percentages can be used. In several aspects of the presentinvention, the cadmium content of the metal alloy is a) up to about 0.1weight percent of the metal alloy, and b) less than about 0.05 weightpercent of the metal alloy.

Chromium, if added and/or included in the metal alloy, is present inamounts of at least about 0.0001 weight percent. In several aspects ofthe present invention, the chromium content of the metal alloy is a)less than about 0.1 weight percent of the metal alloy, and b) up toabout 0.02 weight percent of the metal alloy.

Copper, if added to and/or included in the metal alloy, is present inamounts up to about 5 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the copper content of the metal alloy is a) up to about 2.7weight percent of the metal alloy, b) up to about 2 weight percent ofthe metal alloy, c) up to about 1.6 weight percent of the metal alloy,d) up to about 1.5 weight percent of the metal alloy, e) up to about 1weight percent of the metal alloy, f) up to about 0.05 weight percent ofthe metal alloy, g) at least about 0.001 weight percent of the metalalloy, h) at least about 0.1 weight percent of the metal alloy, i) about0.001-2.7 weight percent of the metal alloy, j) about 0.01-2.7 weightpercent of the metal alloy, k) about 0.001-1.6 weight percent of themetal alloy, l) about 0.1-1.6 weight percent of the metal alloy, m)about 1-1.5 weight percent of the metal alloy, n) about 0.001-1 weightpercent of the metal alloy, o) about 0.001-0.5 weight percent of themetal alloy, p) about 0.005-0.6 weight percent of the metal alloy, q)about 0.005-0.1 weight percent of the metal alloy, r) about 0.01-0.1weight percent of the metal alloy, s) about 0.05-0.1 weight percent ofthe metal alloy, t) about 0.005-2.7 weight percent of the metal alloy,u) about 0.005-1.6 weight percent of the metal alloy, and v) about0.1-1.5 weight percent of the metal alloy. When copper is added to themetal alloy, the copper is typically added in the form of brass and/orbronze.

Iron, if added to and/or included in the metal alloy, is added inamounts up to about 1 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the iron content of the metal alloy is a) less than about 0.5weight percent of the metal alloy, b) less than about 0.1 weight percentof the metal alloy, c) up to about 0.02 weight percent of the metalalloy, d) less than about 0.01 weight percent of the metal alloy, e)less than about 0.005 weight percent of the metal alloy, and f) lessthan about 0.002 weight percent of the metal alloy.

Lead, if added to and/or included in the metal alloy, is present in lowlevels, generally less than about 10 weight percent of the metal alloy;however, higher weight percentages can be used. In several aspects ofthe present invention, the lead content of the metal alloy is a) lessthan about 2 weight percent of the metal alloy, b) less than about 1weight percent of the alloy, c) less than about 0.5 weight percent ofthe alloy, d) less than about 0.1 weight percent of the metal alloy, e)less than about 0.075 weight percent of the metal alloy, f) less thanabout 0.06 weight percent of the metal alloy, g) less than about 0.05weight percent of the metal alloy, h) less than about 0.02 weightpercent of the metal alloy; i) less than about 0.01 weight percent ofthe metal alloy, j) less than about 0.001 weight percent of the metalalloy, and k) about 0.001-0.1 weight percent.

Magnesium, if added to and/or included in the metal alloy, is present inamounts up to about 5 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the magnesium content of the metal alloy is a) up to about 2weight percent of the metal alloy, b) up to about 1 weight percent ofthe metal alloy, c) up to about 0.4 weight percent of the metal alloy,d) up to about 0.1 weight percent of the metal alloy, e) about 0.1-0.4weight percent of the metal alloy, f) about 0.01-0.4 weight percent ofthe metal alloy, and g) about 0.001-0.1 weight percent of the metalalloy. When magnesium is added to the metal alloy, the magnesium istypically added in the form of pure magnesium.

Manganese, if added to and/or included in the metal alloy, is present inamounts up to about 0.1 weight percent of the metal alloy; however,higher weight percentages can be used. In several aspects of the presentinvention, the manganese content of the metal alloy is a) at least about0.0001 weight percent of the metal alloy, b) up to about 0.01 weightpercent of the metal alloy, c) about 0.0001-0.1 weight percent of themetal alloy, d) about 0.001-0.1 weight percent of the metal alloy, ande) about 0.0001-0.01 weight percent of the metal alloy.

Nickel, if added to and/or included in the metal alloy, is present inamounts up to about 5 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the nickel content of the metal alloy is a) up to about 2weight percent of the metal alloy, b) up to about 1 weight percent ofthe metal alloy, c) up to about 0.9 weight percent of the metal alloy,d) up to about 0.7 weight percent of the metal alloy; e) up to about 0.3weight percent of the metal alloy, f) up to about 0.1 weight percent ofthe metal alloy, g) up to about 0.005 weight percent of the metal alloy,h) about 0.001-0.1 weight percent of the metal alloy, i) about 0.001-0.9weight percent of the metal alloy, j) about 0.001-0.3 weight percent ofthe metal alloy, k) about 0.001-0.05 weight percent of the metalalloy, 1) about 0.001-0.005 weight percent of the metal alloy, and m)about 0.01-0.7 weight percent of the metal alloy.

Titanium, if added to and/or included in the metal alloy, is present inamounts up to about 1 weight percent of the metal alloy; however, higherweight percentages can be used. In several aspects of the presentinvention, the titanium content of the metal alloy is a) up to about 0.5weight percent of the metal alloy, b) up to about 0.2 weight percent ofthe metal alloy, c) up to about 0.18 weight percent of the metal alloy;d) up to about 0.15 weight percent of the metal alloy; e) up to about0.1 weight percent of the metal alloy, f) up to about 0.075 weightpercent of the metal alloy, g) up to about 0.05 weight percent of themetal alloy, h) at least about 0.0005 weight percent of the metal alloy,i) about 0.01-0.5 weight percent of the metal alloy, j) about 0.01-0.15weight percent of the metal alloy, k) about 0.0001-0.075 weight percentof the metal alloy, l) about 0.0005-0.05 weight percent of the metalalloy, m) about 0.0005-0.18 weight percent of the metal alloy; n) about0.001-0.05 weight percent of the metal alloy, and o) about 0.005-0.02weight percent of the metal alloy. When titanium is added to a tin andzinc alloy, the titanium is typically added as an alloy such as, but notlimited to, a Zn—Ti alloy.

Zinc, if added to and/or included in the tin alloy, is present inamounts up to about 9-10 weight percent of the metal alloy. Higherweight percentages of zinc transforms the metal alloy to a tin and zincalloy. In several aspects of the present invention, the zinc content ofthe tin alloy is a) up to about 8 weight percent of the tin alloy, b) upto about 7 weight percent of the tin alloy, c) up to about 1.5 weightpercent of the tin alloy, d) less than about 1 weight percent of the tinalloy, e) up to about 0.5 weight percent of the tin alloy, f) about0.001-0.5 weight percent of the tin alloy, and g) less than about 0.2weight percent of the tin alloy.

A general formulation of the corrosion resistant tin alloy by weightpercent includes the following:

Tin 75-99.99 Antimony  0-7.5 Bismuth  0-1.7 Copper  0-5 Lead  0-10

A more specific formulation of the corrosion resistant tin alloy byweight percent includes the following:

Tin 75-99.99 Aluminum  0-5 Antimony  0-7.5 Bismuth  0-1.7 Copper  0-5Lead  0-10 Nickel  0-5 Zinc  0-9

Another and/or alternative more specific formulation of the corrosionresistant tin alloy by weight percent includes the following:

Tin 90-99.99 Aluminum  0-2 Antimony  0-2 Arsenic  0-0.05 Bismuth  0-1.5Boron  0-0.1 Cadmium  0-0.5 Carbon  0-1 Chromium  0-1 Copper  0-2 Iron 0-1 Lead  0-2 Magnesium  0-1 Manganese  0-0.1 Molybdenum  0-0.1 Nickel 0-1 Silicon  0-0.5 Silver  0-0.1 Tellurium  0-0.05 Titanium  0-0.5Vanadium  0-0.1 Zinc  0-7

Still another and/or alternative more specific formulation of the tinalloy by weight percent includes the following:

Tin 90-99.9 Aluminum  0-5 Antimony  0-7.5 Arsenic  0-0.005 Bismuth 0-1.7 Boron  0-0.1 Cadmium  0-0.1 Carbon  0-1 Chromium  0-1 Copper  0-5Iron  0-1 Lead  0-2 Magnesium  0-5 Manganese  0-0.1 Molybdenum  0-0.1Nickel  0-5 Silicon  0-0.5 Silver  0-0.005 Tellurium  0-0.05 Titanium 0-1 Vanadium  0-0.1 Zinc  0-9

A few examples of the metal alloy composition by weight percent whichhave exhibited the desired characteristics as mentioned above are setforth as follows:

Alloy Ingredients A B C D E Tin Bal. Bal. Bal. Bal. Bal. Aluminum ≦0.01≦0.01 ≦0.05 0 0 Antimony ≦1 ≦0.1 ≦0.1 ≦0.05 ≦0.05 Bismuth ≦0.05 ≦0.05≦0.01 ≦0.01 ≦0.01 Copper ≦0.5 ≦0.05 0 1 0 Iron ≦0.1 ≦0.005 0 0 0 Lead ≦1≦0.1 ≦0.1 ≦0.1 ≦2 Nickel ≦0.005 ≦0.05 ≦0.05 ≦0.005 ≦0.05 Zinc ≦1 ≦2 ≦3≦0.5 ≦1 Alloy Ingredients F G H I J Tin Bal. Bal. Bal. Bal. Bal.Aluminum ≦0.01 ≦0.01 0 0 ≦0.05 Antimony ≦0.1 ≦0.01 ≦0.05 ≦0.05 ≦0.1Bismuth ≦0.05 ≦0.01 ≦0.01 ≦0.01 ≦0.1 Copper ≦0.5 0 0 0 ≦0.5 Iron ≦0.0050 0 0 ≦0.05 Lead ≦0.1 ≦0.1 ≦0.1 ≦0.05 ≦1 Nickel 0 0 0 0 ≦1 Zinc ≦1 ≦1 ≦1≦1 ≦9 Alloy Ingredients K L M N O Tin Bal. Bal. Bal. Bal. Bal. Aluminum≦0.01 ≦0.01 ≦0.05 0.0 0.0 Antimony ≦1.0 ≦0.1 ≦0.1 ≦0.05 ≦0.05 Bismuth≦0.05 ≦0.05 ≦0.01 ≦0.01 ≦0.01 Copper ≦0.5 ≦0.5 0.0 1.0 0.0 Iron ≦0.1≦0.005 ≦0.0 ≦0.0 ≦0.0 Lead ≦1.0 ≦0.1 ≦0.1 ≦0.1 ≦2.0 Nickel ≦0.005 ≦0.0≦0.0 ≦0.005 ≦0.0 Zinc ≦1 ≦2 ≦3 ≦0.5 ≦1

One formulation of the corrosion resistant tin alloy includes by weightpercent at least 75% tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic;0-1.5% bismuth; 0-0.1% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5%chromium; 0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.1silver;0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium; 0-0.1% vanadium;and 0-9% zinc. Another and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.5% aluminum; 0-2%antimony; 0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1%cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-1%lead; 0-0.4magnesium, 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.5% silicon; 0-0.1% silver; 0-0.01% sulfur; 0-0.01% tellurium;0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Still another and/oralterative formulation of the corrosion resistant tin alloy includes atleast 90% tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5%bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium;0-2% copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.05% silver; 0-0.02%sulfur; 0-0.04% tellurium; 0-0.15% titanium; 0-0.05% vanadium; and 0-5%zinc. Yet another and/or alterative formulation of the corrosionresistant tin alloy includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8%antimony; 0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05%cadmium; 0-0.1% carbon; 0-0.05% chromium; 0-1% copper; 0-1% iron; 0-5%lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.05% molybdenum; 0-0.9%nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.01sulfur; 0-0.01% tellurium;0-0.1% titanium; 0-0.01% vanadium; and 0-2% zinc. Still yet anotherand/or alterative formulation of the corrosion resistant tin alloyincludes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.05% chromium; 0-1% copper; 0-0.5% iron; 0-0.5% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1%titanium; 0-0.01% vanadium; and 0-2% zinc. A further and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99.9% tin;0-0.01% aluminum; 0-1% antimony and/or bismuth; 0-0.1% copper; 0-0.05%iron; 0-0.5% lead; 0-0.05% magnesium; 0-0.05% manganese; 0-0.1% nickel;and 0-0.1% zinc. Yet a further and/or alterative formulation of thecorrosion resistant tin alloy includes 98-99.99% tin; 0-0.1% aluminum;0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001%cadmium; 0-0.01% carbon; 0-0.01chromium; 0-0.1% copper; 0-0.05% iron;0-0.05% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001%molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.001%sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and0-1% zinc. Still yet a further and/or alterative formulation of thecorrosion resistant tin alloy includes at least 90% tin and 0.01-0.1%lead. Another and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.9% tin and 0.001-0.1% lead. Still anotherand/or alterative formulation of the corrosion resistant tin alloyincludes 90-99.9% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7% copper;0.001-0.1% lead; and 0-1.5% zinc. Yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.9% tin;less than 0.001% aluminum; 0-7.5% antimony; 0-1.7% bismuth; less than0.05% cadmium; 0-2.7% copper; 0.001-0.1% lead; and 0-1.5% zinc. Stillyet another and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-2.5% antimony; 0-0.5% bismuth; 0-2.7%copper; 0-0.1% iron; 0.001-0.10% lead; and 0.5-1.5% zinc. A furtherand/or alterative formulation of the corrosion resistant tin alloyincludes 90-99.9% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7% copper;0-0.1% iron; 0.01-0.1% lead; and 0-1.5% zinc. Yet a further and/oralterative formulation of the corrosion resistant tin alloy includes90-99.95% tin; 0-7.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-1%iron; 0-0.5% lead; and 0-0.5% zinc. Still a further and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.95% tin;0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-1% iron; 0-0.5% lead;and 0-7% zinc. Still yet a further and/or alterative formulation of thecorrosion resistant tin alloy includes 90-99.95% tin; 0-0.5% antimonyand/or bismuth; 0-1% copper; 0-1% iron; 0-0.05% lead; and 0-1.5% zinc.Another and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.95% tin; 0.005-0.5% antimony; bismuth and/orcopper; 0-0.05% lead; and 0-0.5% zinc. Still another and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.9% tin;0-5% aluminum; 0-7.5% antimony; 0-0.005% arsenic; 0-1.7% bismuth; 0-0.1%cadmium; 0-5% copper; 0-1% iron; 0-2% lead; 0-5% magnesium; 0-5% nickel;0-0.005% silver; 0-1% titanium; and 0-9% zinc. Yet another and/oralterative formulation of the corrosion resistant tin alloy includes95-99.9% tin; 0-0.01% aluminum; 0-0.5% antimony; 0-0.5% bismuth;0-0.005% iron; 0-0.1% lead; 0-0.1% nickel; and 0-2% zinc. Still yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 199-99.9% tin; 0-0.4% antimony; 0-0.2% bismuth; 0-0.001%iron; 0-0.05% lead; 0-0.001% nickel; and 0-0.2% zinc. A further and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-0.01% aluminum; 0-1% antimony; 0-0.05% bismuth; 0-0.5%copper; 0-0.1% iron; 0-1% lead; 0-0.005% nickel; and 0-1% zinc. Yet afurther and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.5% aluminum; 0-2% antimony; 0-0.01%arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon;0-0.5% chromium; 0-2% copper; up to 1% iron; less than 1% lead; 0-0.4%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.15%titanium; 0-0.1% vanadium; and 0-9% zinc. Still a further and/oralterative formulation of the corrosion resistant tin alloy includes98-99.9% tin; 0-0.01% aluminum; 0-1% antimony and/or bismuth; 0-0.1%copper; less than 0.05% iron; less than 0.5% lead; 0-0.05% magnesium;0-0.05% manganese; 0-0.1% nickel; and 0-0.1% zinc. Still yet a furtherand/or alterative formulation of the corrosion resistant tin alloyincludes 99-99.9% tin; 0.001-0.8% antimony and/or bismuth; 0-0.02%copper; 0-0.001% iron; and 0-0.08% lead; 0-0.001% nickel; and 0-0.001%zinc. Another formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-5% aluminum; 0-7.5% antimony; 0-0.005% arsenic; 0-1.7%bismuth; 0-0.005% cadmium; 0-5% copper; 0-1% iron; 0-2% lead; 0-5%magnesium; 0-5% nickel; 0-0.005% silver; 0-1% titanium; and 0-9% zinc.Yet another and/or alterative formulation of the corrosion resistant tinalloy includes 95-99.9% tin; 0-0.05% aluminum; 0-0.2% antimony; 0-0.1%bismuth; 0-0.1% copper; 0-0.1% iron; 0-0.2% lead; 0-0.1% nickel; and0-9% zinc. Still yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 75-99.9% tin; 0-5% aluminum;0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-10% lead; 0-5% nickel;0-0.5 titanium; and 0-9% zinc. A further and/or alterative formulationof the corrosion resistant tin alloy includes 90-99.9% tin; 0-2%aluminum; 0-2% antimony; 0-0.05% arsenic; 0-1.5% bismuth; 0-0.1% boron;0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-2% copper; 0-1% iron; 0-2%lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium;0-0.1% vanadium; and 0-7% zinc. Yet a further and/or alterativeformulation of the corrosion resistant tin alloy includes at least 90%tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth;0-0.5% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2%copper; 0-1% iron; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.05silver; 0-0.02% sulfur;0-0.04% tellurium; 0-0.15% titanium; 0-0.05% vanadium; and 0-5% zinc.Still a further and/or alterative formulation of the corrosion resistanttin alloy includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony;0-0.005% arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1%carbon; 0-0.05% chromium; 0-1% copper; 0-0.5% iron; 0-0.5% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.05% molybdenum; 0-0.3% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1%titanium; 0-0.01% vanadium; and 0-2% zinc. Still yet a further and/oralterative formulation of the corrosion resistant tin alloy includes98-99.99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001%silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05%titanium; 0-0.001% vanadium; and 0-1% zinc. Another and/or alterativeformulation of the corrosion resistant tin alloy includes at least 75%tin; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic; 0-1.5% bismuth;0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2%copper; 0-1% iron; 0-2% lead; 0-0.4% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.1% silver; 0-0.02% sulfur;0-0.04% tellurium; 0-0.15% titanium; 0-0.1% vanadium; and 0-9% zinc. Yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 95-99.99% tin; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005%arsenic; 0-0.5% bismuth; 0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon;0-0.05% chromium; 0-1% copper; 0-1% iron; 0-5% lead; 0-0.01% magnesium;0-0.01% manganese; 0-0.05% molybdenum; 0-0.9% nickel; 0-0.5% silicon;0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium;0-0.01% vanadium; and 0-2% zinc. Still another and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99.99% tin;0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic;0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium;0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon;0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and 0-1% zinc. Still yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.9% tin;0-0.5% antimony; 0-1.5% bismuth; 0.00-1% lead; and 0-0.001% zinc. Afurther and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.1%iron; 0-1% lead; and 0-0.5% zinc. Yet further and/or alterativeformulation of the corrosion resistant tin alloy includes 90-99.9% tin;0-7.5% antimony; 0-2.7% copper; and 0-1% lead. Still a further and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-2.5% antimony; 0-2% copper; 0-1% lead; and 0-0.5% zinc.Still yet a further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5%bismuth; 0-0.1% iron; 0-1% lead; an 0-0.5% zinc. Another and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-1% antimony; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead.Still another and/or alterative of the corrosion resistant tin alloyincludes 90-99.9% tin; 0-0.5% bismuth; 0-0.1% iron; and 0-1% lead. Yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.01%iron; 0.001-0.05% lead; and 0-0.5% zinc. Still yet another and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-0.5% antimony; 0-1.7% bismuth; 0-0.02% lead; and0-0.001% zinc. A further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5%bismuth; 0-0.005% cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead;0-0.005% nickel; 0-0.001% silver; 0-0.001% sulfur; and 0-0.5% zinc.Still a further and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.9% tin; 0-7.5% antimony; and 0-2.7% copper. Yeta further and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-2.5% antimony; 0-2% copper; and 0-0.5%zinc. Still yet a further and/or alterative formulation of the corrosionresistant tin alloy includes 90-99.9% tin; 0-0.5% antimony; 0-1.5%bismuth; 0-0.005% cobalt; 0-0.02% lead; 0-0.005% nickel; 0-0.001%silver; 0-0.001% sulfur; and 0-0.001% zinc. Another formulation of thecorrosion resistant tin alloy includes 90-99.9% tin and 0-0.1% lead.Still another and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.9% tin and 0-0.01% lead. Yet another and/oralterative formulation of the corrosion resistant tin alloy includes90-99.9% tin; 0-5.5% antimony; 0-0.5% aluminum; 0-1.7% bismuth; 0-2.7%copper; 0-0.4% magnesium; 0-1% nickel; and 0-0.15% titanium. Still yetanother and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-0.75% antimony; 0-0.5% bismuth; 0-0.005%cobalt; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-0.005% nickel;0-0.001silver; 0-0.001% sulfur; and 0-0.5% zinc. A further and/oralterative formulation of the corrosion resistant tin alloy includes90-95% tin; 0-0.25% aluminum; 0-1.5% copper; 0-0.02% chromium; 0-0.01%iron; 0-0.01% lead; 0-0.01% manganese; 0-0.018% titanium; and 0-9% zinc.Still a further and/or alterative formulation of the corrosion resistanttin alloy includes 0-2.5% antimony, 0-0.5% bismuth, 0-2.7% copper;0-0.1% iron; 0.001-0.1% lead; 0.5-1.5% zinc and the remainder tin.Another and/or alterative formulation of the corrosion resistant tinalloy includes 90-99.9% tin; 0-7.2% antimony; 0-1.7% bismuth; 0-2.7%copper; 0-0.1% iron; 0.001-0.1% lead; and 0-1.5% zinc. Still anotherand/or alterative formulation of the corrosion resistant tin alloyincludes at least about 95% tin; 0.001-0.1% lead, and at least about0.5% stabilizer. Yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 0-2.5% antimony, 0-0.5% bismuth,0-2.7% copper, 0-0.1% iron, 0.001-0.1% lead, 0-1.5% zinc and theremainder tin. Still yet another and/or alterative formulation of thecorrosion resistant tin alloy includes 90-99.95% tin; 0-7.2% antimony;0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron; 0.001-0.1% lead; and 0-0.5%zinc. A further and/or alterative formulation of the corrosion resistanttin alloy includes 90-99.95% tin; 0-7.2% antimony; 0-1.7% bismuth; and0.001-0.05% lead. Still a further and/or alterative formulation of thecorrosion resistant tin alloy includes 95-99.9% tin; 0-0.1% aluminum;0-1% antimony; 0-0.5% bismuth; 0-0.5% copper; 0-0.1% iron; 0-0.5% lead;0-0.1% nickel; and 0-0.2% zinc. Still yet a further and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99.9% tin;0-0.4% antimony; 0-0.2% bismuth; 0-0.1% copper; 0-0.01% iron; 0-0.05%lead; 0-0.01% nickel; and 0-0.05% zinc. Another and/or alterativeformulation of the corrosion resistant tin alloy includes 75-99.99% tin;0-5% aluminum; 0-7.5% antimony; 0-1.7% bismuth; 0-5% copper; 0-10% lead;0-5% nickel; 0-0.5% titanium; and 0-9% zinc. Still another and/oralterative formulation of the corrosion resistant tin alloy includes98-99% tin; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001%arsenic; 0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01%chromium; 0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium;0-0.001% manganese; 0-0.001% molybdenum; 0-0.1% nickel; 0-0.001%silicon; 0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium;0-0.05titanium; 0-0.001% vanadium; and 0-1% zinc. Yet another and/oralterative formulation of the corrosion resistant tin alloy includes50-99.999% tin; 0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1%boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5%copper; 0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05%tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-9zinc. Yet anotherand/or alterative formulation of the corrosion resistant tin alloyincludes 90-99.999% tin; 0-7.5% aluminum; 0-2% antimony; 0-0.05%arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1%chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1%silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1% vanadium; and 0-9%zinc. Still another and/or alterative formulation of the corrosionresistant tin alloy includes 75-99.999% tin; 0-7.5% aluminum; 0-2%antimony; 0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium;0-1% carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; 0-0.1%vanadium; and 0-10% zinc. Yet another and/or alterative formulation ofthe corrosion resistant tin alloy includes 75-99.999% tin; 0-7.5%aluminum; 0.001-5% antimony, bismuth, cadmium and/or copper; 0-2% lead;0-1% nickel; and 0-10% zinc. Still yet another and/or alterativeformulation of the corrosion resistant tin alloy includes 95-99.999%tin; 0-2% aluminum; 0.001-2% antimony, bismuth, cadmium and/or copper;0-1% lead; 0-1% nickel; and 0-2% zinc. Still another and/or alterativeformulation of the corrosion resistant tin alloy includes 98-99% tin;0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic;0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.01% chromium;0-0.1% copper; 0-0.05% iron; 0-0.05% lead; 0-0.001% magnesium; 0-0.001%manganese; 0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon;0-0.001% silver; 0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium;0-0.001% vanadium; and 0-1% zinc.

A general formulation of the corrosion resistant tin and zinc alloy byweight percent includes the following:

Tin 15-90 Zinc 10-85 Antimony  0-7.5 Bismuth  0-5 Copper  0-5

One more specific formulation of the corrosion resistant tin and zincalloy by weight percent includes the following:

Tin 15-90 Zinc 10-85 Aluminum  0-5 Antimony  0-7.5 Bismuth  0-5 Cadmium 0-1 Copper  0-5 Nickel  0-5

Another and/or alterative specific formulation of the corrosionresistant tin and zinc alloy by weight percent includes the following:

Tin 20-80 Zinc 20-80 Aluminum  0-2 Antimony  0-1 Arsenic  0-0.05 Bismuth 0-1 Boron  0-0.1 Cadmium  0-0.1 Carbon  0-0.5 Chromium  0-0.5 Copper 0-2 Iron  0-1 Lead  0-1 Magnesium  0-1 Manganese  0-0.1 Molybdenum 0-0.1 Nickel  0-1 Silicon  0-0.5 Silver  0-0.1 Tellurium  0-0.05Titanium  0-0.5 Vanadium  0-0.1

Still another and/or alterative specific formulation of the corrosionresistant tin and zinc alloy by weight percent includes the following:

Tin 30-85 Zinc 15-70 Aluminum  0-1 Antimony  0-1 Arsenic  0-0.01 Bismuth 0-1 Boron  0-0.1 Cadmium  0-0.1 Carbon  0-0.5 Chromium  0-0.1 Copper 0-1 Iron  0-0.1 Lead  0-0.1 Magnesium  0-1 Manganese  0-0.01 Molybdenum 0-0.1 Nickel  0-0.1 Silicon  0-0.5 Silver  0-0.01 Tellurium  0-0.05Titanium  0-0.05 Vanadium  0-0.1

Yet another and/or alterative specific formulation of thecorrosion-resistant tin and zinc alloy by weight percent includes thefollowing:

Tin   70-90 Zinc    9-30 Aluminum 0.001-0.01 Antimony 0.001-0.8 Copper0.001-0.02 Bismuth 0.001-0.005 Boron    0-0.05 Silver    0-0.005 Carbon   0-0.05 Chromium    0-0.05 Iron    0-0.005 Magnesium    0-0.05Manganese    0-0.01 Molybdenum    0-0.05 Silicon    0-0.05 Tellurium   0-0.01 Titanium    0-0.05 Vanadium    0-0.05 Arsernc    0-0.005Cadmium    0-0.01 Nickel    0-0.005 Lead  0.01-0.1

Still yet another and/or alterative specific formulation of thecorrosion-resistant tin and zinc alloy by weight percent includes thefollowing:

Tin  79.5-81.5 Zinc  18.5-20.5 Aluminum 0.002-0.008 Antimony  0.6-0.7Arsenic    0-0.001 Bismuth 0.002-0.005 Cadmium    0-0.001 Copper0.005-0.02 Iron    0-0.001 Lead  0.02-0.08 Nickel    0-0.001 Silver   0-0.001

Examples of the tin and zinc alloy composition by weight percentinclude:

Ingredients A B C D E F G H Zinc 10 15 20 25 30 35 40 45 Tin 90 85 80 7570 65 60 55 Aluminum ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Antimony≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Bismuth ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 Copper ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Lead ≦0.1≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 Ingredients I J K L M N O P Zinc 5055 60 65 70 75 80 85 Tin 50 45 40 35 30 25 20 15 Aluminum ≦0.5 ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Antimony ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5≦0.5 Bismuth ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Copper ≦0.5 ≦0.5≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 ≦0.5 Lead ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1 ≦0.1≦0.1

One formulation of the corrosion resistant tin and zinc alloy includesby weight percent 20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2% antimony;0-0.02% arsenic; 0-1.5% bismuth; 0-0.1% boron; 0-0.1% cadmium; 0-0.5%carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-1% lead; 0-0.4%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5%silicon; 0-0.5% silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15%titanium; and 0-0.05% vanadium. Another and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 30-70% tin;30-70% zinc; 0-0.4% aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5%bismuth; 0-0.05% boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium;0-1% copper; 0-0.6% iron; 0-0.1% magnesium; 0-0.1% manganese; 0-0.05%molybdenum; 0-0.9% nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0-0.1% titanium; and 0-0.01% vanadium; a thetin plus zinc content is at least 90 weight percent of the alloy. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-1%antimony and/or bismuth; 0-0.001% arsenic; 0-0.01% boron; 0-0.005%cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper; 0-0.05% iron;0-0.1% lead; 0-0.01magnesium; 0-0.01% manganese; 0-0.01% molybdenum;0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.001% sulfur;0-0.001% tellurium; 0-0.05% titanium; and 0-0.001% vanadium; and the tinplus zinc content is at least 95 weight percent of the alloy. Yetanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 45-55% zinc; 45-55% tin; 0-0.4% aluminum; 0-0.8%antimony and/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001%cadmium; 0-0.01% carbon; 0-0.05% copper; 0-0.001 iron; 0-0.08% lead;0-0.001% magnesium; 0-0.001% manganese; 0-0.001% molybdenum; 0-0.9%nickel; 0-0.001% silicon; 0-0.005% silver; 0-0.001% sulfur; 0-0.001%tellurium; 0-0.05% titanium and 0-0.001%vanadium; and the tin contentplus the zinc content is at least 99% of the alloy. Still yet anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 30-85% tin; 15-70% zinc; 0-0.5% aluminum; 0-2% antimony;0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.1%carbon; 0-0.1% chromium; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4%magnesium; 0-0.1% manganese; 0-0.05% molybdenum; 0-1% nickel; 0-0.5%silicon; 0-0.05% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0-0.15%titanium; and 0-0.05% vanadium. A further and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 30-65% tin;35-70% zinc; 0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.05%arsenic; 0-0.01% cadmium; 0-0.5% copper; less than 0.05% iron; less than0.1% lead; 0-0.1% magnesium; 0-0.1% manganese; 0-0.5% nickel; 0-0.05%silver; 0-0.05% titanium; and the tin plus zinc content is at least 98%of the metal alloy. Still a further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 40-60% tin; 40-60%zinc; 0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.005% arsenic;0-0.005% cadmium; 0-0.2% copper; 0-0.05% iron; 0-0.1% lead; 0-0.001%magnesium; 0-0.001% manganese; 0-0.05% nickel; 0-0.005% silver; 0-0.05%titanium; and the tin plus zinc content is at least 99% of the metalalloy. Yet a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 60-90% tin 9 to 10-40% zinc;0-0.5% aluminum; 0-2% antimony; 0-0.01% arsenic; 0-15% bismuth; 0-0.05%boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; upto 1% iron; less than 0.5% lead; 0-0.4% magnesium; 0-0.1% manganese;0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.01%sulfur; 0-0.01% tellurium; 0-0.15% titanium; and 0-0.1% vanadium. Stillyet a further and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 70-90% tin; 9 to 10-30% zinc; 0-0.1%aluminum; 0-1% antimony and/or bismuth; 0-0.05% arsenic; 0-0.01%cadmium; 0-0.5% copper; less than 0.05% iron; less than 0.1% lead;0-0.1% magnesium; 0-0.1% manganese; 0-0.5% nickel; 0-0.05% silver;0-0.05% titanium; and the tin plus zinc content is at least 95% of themetal ahoy. Yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 75-85% tin; 15-25% zinc;0.001-0.01% aluminum; 0.001-0.8% antimony and/or bismuth; 0-0.005%arsenic; 0-0.001% cadmium; 0.005-0.02% copper; 0-0.001 iron; 0.01-0.08%lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001% nickel; 0-0.01silver; 0-0.001% titanium; and the tin plus zinc content is at least 98%of the metal alloy coating. Another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 15-35% tin; 65-85%zinc; 0-7.5% antimony; 0-1.7% bismuth. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-35% tin; 65-85% zinc; and 0.01-0.5% antimony and/or bismuth. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 15-35% tin; 65-85% zinc; 0.01-0.5% antimonyand/or bismuth; and less than 2% copper and/or iron. Still yet anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 15-35% tin; 65-85% zinc; 0-0.5% antimony; 0-0.5% bismuth;and less than 0.01% lead. A further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 15-35% tin; 65-85%zinc; 0-0.5% antimony; 0-0.5% bismuth; less than 2% copper and/or iron;and less than 0.01% lead. Yet a further and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 15-35% tin;65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron;and 0-0.05% lead. Another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 70-90% tin; 9 to 10-30%zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and0-0.05% lead. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 80-90% tin; 9 to 10-20%zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and0-0.05% lead. Yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 70-90% tin; 9 to 10-30%zinc; 0-2.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; and0-0.05% lead. Still yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 70-90% tin; 9 to 10-30%zinc; 0.5-7.5% antimony; 0.5-1.7% bismuth; 0-2% copper; 0-0.1% iron; and0-0.05lead. A further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 80-90% tin; 9 to 10-20% zinc;0-7.5% antimony; 0-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.01%lead. A further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-70% tin; 30-85% zinc; 0-7.5%antimony; 0-1.7% bismuth; 0-5% copper; 0-0.01% iron; 0-0.05% lead; and0-5% nickel. Yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-70% tin; 30-85% zinc;0-0.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; 0-0.01% lead;and 0-1% nickel. Still a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 35-70% tin; 30-65% zinc;0-0.5% antimony; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; 0-0.05% lead;and 0-1% nickel. Still yet a further and/or alternative formulation ofthe corrosion resistant tin and zinc ahoy includes 45-55% tin; 45-55%zinc; 0-0.5% antimony and/or bismuth; 1-1.5% copper; 0-0.1% iron;0-0.01% lead; 0.3-0.9% nickel; and the tin content plus zinc content atleast 95% of the metal alloy. Another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 20-90% tin; 9 to10-80% zinc; 0-0.5% aluminum; 0-1% antimony; 0-2.7% copper; and 0-0.15%titanium. Still another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-90% tin; 9 to 10-80% zinc;0-0.3% aluminum; 0-5.5% antimony; and 0-1% copper. Yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-90% tin 9 to 10-80% zinc; 0-5% aluminum; 0-5.5% antimony;0-1.7% bismuth; 0-5% copper; 0-0.1% iron; 0-0.05% lead; 0-5% magnesium;0-5% nickel; and 0-1% titanium. Still another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-75% tin; 25-80% zinc; 0-1% aluminum; 0-5.5% antimony; 0-1.7% bismuth;0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-1% magnesium; 0-1% nickel;and 0-0.5% titanium. Still yet another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 20-80% tin; 20-80%zinc; 0-0.5% aluminum; 0-5.5% antimony; 0-1.5% bismuth; 0-2.7% copper;0-0.1% iron; 0-0.01% lead; 0-0.4% magnesium; 0-1% nickel; and 0-0.15%titanium. A further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 35-70% tin; 30-65% zinc; 0-0.3%aluminum; 0.05-1% antimony and/or bismuth; 0-1% copper; 0-0.1% iron;0-0.01% lead; 0-0.4% magnesium; 0-0.7% nickel; 0-0.15% titanium; and thetin plus zinc content is at least 90% of the metal alloy. Yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 15-90% tin; 9 to 10-85% zinc; 0-5% aluminum; 0-7.5%antimony; 0-1.7% bismuth; 0-5% copper; 0-1% iron; 0-1% lead; 0-5%magnesium; 0-5% nickel; and 0-1% titanium. Still yet a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 9 to 10-70% tin; 30-90% zinc; 0-0.25% aluminum; 0-0.02%chromium; 0-1.5% copper; 0-0.01% iron; 0-0.01% lead; 0-0.01% magnesium;and 0-0.18% titanium. Another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 9 to 10-70% tin; 30-90%zinc; 0-0.25% aluminum; 0-0.02% chromium; 0-1.5% copper; 0-0.01% iron;0-0.01% lead; 0-0.01% magnesium; and 0-0.18% titanium. Still anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 15-90% tin; 9 to 10-0-85% zinc; 0-0.01% aluminum; 0-1%antimony, 0-0.005% arsenic; 0-0.01% bismuth; 0-0.05% cadmium; 0-0.05%copper; 0-0.005% iron; 0-0.1% lead; 0-0.005% nickel; and 0-0.005%silver. Yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 70-90% tin; 9 to 10-30% zinc;0-0.01% aluminum; 0.001-0.8% antimony; 0-0.005% arsenic;0.001-O.005%bismuth; 0-0.01% cadmium; 0-0.02% copper; 0-0.005% iron;0-0.1% lead; 0-0.005% nickel; and 0-0.005% silver. Still yet anotherand/or alternative formulation of the corrosion resistant tin and zincahoy includes 79.5-81.5% tin; 18.5-20.5% zinc; 0.002-0.008% aluminum;0.6-0.7% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001%cadmium; 0.005-0.02% copper; 0-0.001% iron; 0.02-0.08% lead; 0-0.001%nickel; and 0-0.001% silver. A further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 70-90% tin; 9 to10-30% zinc; 0-0.01% aluminum; 0-1% antimony; 0-0.005% arsenic; 0-0.01%bismuth; 0-0.01% cadmium; 0-0.5% copper; 0-0.005% iron 0-0.1% lead;0-0.005% nickel; and 0-0.005% silver. Yet further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes60-90% tin; 9 to 10-40% zinc; 0-0.5% aluminum; 0-2% antimony; 0-0.01%arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.05% carbon;0.0-0.5% chromium; 0-2% copper; up to 1% iron; less than 0.5% lead;0-0.4% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel;0-0.5% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium;0-0.15% titanium; and 0-0.1% vanadium. Still a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 70-90% tin; 9 to 10-30% zinc; 0-0.1% aluminum; 0-1% antimonyand/or bismuth; 0-0.05% arsenic; 0-0.01% cadmium; 0-0.5% copper; lessthan 0.05% iron; less than 0.1% lead; 0-0.1% magnesium; 0-0.1%manganese; 0-0.5% nickel; 0-0.5% silicon; 0-0.05% silver; 0-0.05%titanium; and the tin plus zinc content is at least 95% of the metalalloy. Still yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 75-85% tin; 15-25% zinc;0.001-0.01% aluminum; 0.001-0.8% antimony and/or bismuth; 0-0.005%arsenic; 0-0.001% cadmium; 0.005-0.02% copper; 0-0.0015% iron;0.01-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese; 0-0.001%nickel; 0-0.5% silicon; 0-0.01% silver; 0-0.001% titanium; and the tinplus zinc content is at least 98% of the metal alloy. Another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-90% tin; 9 to 10-0-85% zinc; 0-2% aluminum; 0-2% antimony;0-1.7% bismuth; 0-2% copper; 0-0.05% lead; 0-2% magnesium; 0-2% nickel;and 0-1% titanium. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-90% tin; 9to 10-0-85%zinc; 0-1% aluminum; 0-2% antimony; 0-1.7% bismuth; 0-2% copper; 0-1%iron; 0-0.5% lead; 0-1magnesium; 0-1% nickel; and 0-0.5% titanium. Yetanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 20-90% tin; 9 to 10-80% zinc; 0-0.51% aluminum;0-2% antimony; 0-1.5% bismuth; 0-0.01% boron; 0-0.1% cadmium; 0-0.5%carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5%silicon; and 0-0.15% titanium; and 0-0.1% vanadium. Still another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-65% tin; 30-80% zinc; 0-0.3% aluminum; 0-1% antimony and/orbismuth; 0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1%manganese; 0-0.7% nickel; 0-0.15% titanium; and the tin plus zinccontent is at least 95% of the metal alloy. Still yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-50% tin; 50-80% zinc; 0-0.3% aluminum; 0.005-0.5% antimonyand/or bismuth; 0-0.05% cadmium; 0-0.2% copper; 0-0.6% iron; 0-0.4%lead; 0-0.1% magnesium; 0-0.05% manganese; 0-0.1% nickel; 0-0.1%silicon; 0-0.15% titanium; and the tin plus zinc content is at least 95%of the metal alloy. A further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-70% tin; 30-75% zinc;0.0005-2% aluminum; 0.001-2% antimony; 0.0001-1% bismuth; 0-2% copper;0-0.5% lead; and 0.0001-0.1% titanium. Yet a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes40-60% tin; 40-60% zinc; 0.0005-0.75% aluminum; 0.001-1% antimony;0-0.01% arsenic; 0.0001-0.2% bismuth; 0-0.01% cadmium; 0.001-1% copper;0-0.01% chromium; 0-0.1% iron; 0-0.1% lead; 0-0.01% manganese; 0-0.2%nickel; 0-0.01% silver; and 0.0005-0.05% titanium. Still yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 25-70% tin; 30-75% zinc; 0-0.5% aluminum; 0-0.5% copper;0-0.1% lead; and 0-0.05% titanium. Another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes30-70% tin; 30-70% zinc; 0.0001-0.5% aluminum; 0.001-2% antimony;0-0.01% arsenic; 0.0001-1% bismuth; 0-0.01% boron; 0-0.01% cadmium;0-0.05% carbon; 0-0.05% chromium; 0-2% copper; 0-0.1% iron; 0-0.05%lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-1%nickel; 0-0.01% silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01%tellurium; 0.0001-0.1% titanium; and 0-0.01% vanadium. Still anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 40-60% tin; 40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8%antimony; 0-0.005% arsenic; 0.001-0.05% bismuth; 0-0.005% cadmium;0.005-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.05% nickel; 0-0.005%silver; and 0.0005-0.05% titanium. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes48-52% tin; 48-52% zinc; 0.005-0.24% aluminum; 0.05-0.64% antimony;0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001% cadmium; 0.01-0.3%copper; 0-0.016% iron; 0-0.08% lead; 0-0.001% nickel; 0-0.001 silver;and 0.001-0.02titanium. Yet another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 15-90% tin; 9 to10-85% zinc; 0-5% aluminum; 0-5% antimony; 0-5% bismuth; 0-1% cadmium;0-5% copper; 0-1% iron; 0-1% lead; and 0-1% nickel. Still another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 30-85% tin; 15-70% zinc; 0-1% antimony; 0-0.1% arsenic; 0-1%bismuth; 0-0.1% cadmium; 0-1% copper; 0-0.1% iron; 0-0.1% lead; 0-0.1%manganese; 0-0.1% nickel; 0-0.1% silver; and 0-0.05% titanium. Still yetanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 30-80% tin; 20-70% zinc; 0-0.5% aluminum; 0-0.5%antimony; 0-0.5% bismuth; 0-0.5% copper; and 0-0.1% lead. A furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 30-85% tin; 15-70% zinc; 0-0.5% aluminum; 0-2 antimony;0-0.01% arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.1%carbon; 0-0.1% chromium; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4%magnesium; 0-0.1% manganese; 0-0.05% molybdenum; 0-1% nickel; 0-0.5%silicon; 0-0.05% silver; 0-0.01% tellurium; 0-0.15% titanium; and0-0.05% vanadium. Yet a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 30-65% tin; 35-70% zinc;0-0.1% aluminum; 0-1% antimony and/or bismuth; 0-0.05% arsenic; 0-0.01%cadmium; 0-0.5% copper; 0-0.05% iron; 0-0.1% lead; 0-0.1% magnesium;0-0.1% manganese; 0-0.5% nickel; 0-0.05% silver; 0-0.05% titanium; andthe tin plus zinc content is at least 98% of the metal alloy. Still yeta further and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 40-60% tin; 40-60% zinc; 0-0.4% aluminum; 0-0.8%antimony and/or bismuth; 0-0.005% arsenic; 0-0.005% cadmium; 0-0.2%copper; 0-0.001% iron; 0.01-0.08% lead; 0-0.001% magnesium, 0-0.001%manganese; 0-0.05% nickel; 0-0.005% silver; 0-0.05% titanium; and thetin plus zinc content is at least 99% of the metal alloy. Another and/oralternative formulation of the corrosion resistant tin and zinc ahoyincludes 15-90% tin; 9 to 10-85% zinc; 0-5% aluminum; 0-7.5% antimony;0-5% bismuth; 0-1% cadmium; 0-5% copper; 0-5% nickel; and 0-0.5%titanium. Still another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-80% tin; 20-80% zinc; 0-2%aluminum; 0-1% antimony; 0-0.05% arsenic; 0-1% bismuth; 0-0.1% boron;0-0.1% cadmium; 0-0.5% carbon; 0-0.5% chromium; 0-2% copper; 0-1% iron;0-1% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-1%nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5%titanium; and 0-0.1% vanadium. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2% antimony; 0-0.02% arsenic;0-1.5% bismuth; 0-0.5% boron; 0-0.1% cadmium; 0-0.5% carbon; 0-0.5%chromium; 0-2% copper; 0-1% iron; 0-1% lead; 0-0.4% magnesium; 0-0.01%manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.05% silicon; 0-0.05%silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium; and 0-0.05%vanadium. Still yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 30-70% tin; 30-70% zinc;0-0.4% aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.5% bismuth;0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.1% chromium; 0-1%copper; 0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.05% molybdenum; 0-0.7% nickel; 0-0.01% silicon; 0-0.01% silver;0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.01% vanadium;and the tin plus zinc content is at least 90 weight percent of the metalalloy. Another and/or alternative further formulation of the corrosionresistant tin and zinc alloy includes 40-60% tin; 40-60% zinc; 0-0.4%aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.01% boron;0-0.005% cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper;0-0.05% iron; 0-0.1% lead; 0-0.01% magnesium; 0-0.01% manganese; 0-0.01%molybdenum; 0-0.3% nickel; 0-0.001% silicon; 0-0.001% silver; 0-0.01%sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001% vanadium; and thetin plus zinc content is at least 95 weight percent of the metal alloy.Yet a further and/or alternative formulation of the corrosion resistanttin and zinc alloy includes 45-55% zinc; 45-55% tin; 0-0.4% aluminum;0-0.8antimony and/or bismuth; 0-0.001% arsenic; 0-0.001% boron; 0-0.001%cadmium; 0-0.01% carbon; 0-0.05% copper; 0-0.001 iron; 0-0.08% lead;0-0.001% magnesium; 0-0.001% manganese;0-0.001% molybdenum; 0-0.1%nickel; 0-0.001% silicon; 0-0.005% silver; 0-0.001% sulfur; 0-0.001%tellurium; 0-0.05% titanium; 0-0.001% vanadium; and the tin content plusthe zinc content is at least 99% of the metal alloy. Another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-80% tin; 20-80% zinc; 0-1% aluminum; 0-2% antimony; 0-0.02%arsenic; 0-1.5% bismuth; 0-0.05% boron; 0-0.1% cadmium; 0-0.5% carbon;0-0.5% chromium; 0-2% copper; 0-0.1% iron; 0-1% lead; 0-0.4% magnesium;0-0.1% manganese; 0-0.1% molybdenum; 0-1% nickel; 0-0.5% silicon;0-0.05% silver; 0-0.02% sulfur; 0-0.04% tellurium; 0-0.15% titanium; and0-0.05% vanadium. Yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 30-70% tin; 30-70% zinc;0-0.4% aluminum; 0-0.8% antimony; 0-0.005% arsenic; 0-0.05% bismuth;0-0.1% boron; 0-0.05% cadmium; 0-0.1% carbon; 0-0.1%chromium; 0-1%copper; 0-0.6% iron; 0-0.5% lead; 0-0.1% magnesium; 0-0.1% manganese;0-0.05% molybdenum; 0-0.9% nickel; 0-0.01% silicon; 0-0.01% silver;0-0.01% sulfur; 0-0.01% tellurium; 0-0.1% titanium; 0-0.001% vanadium;and the tin plus zinc content is at least 90 weight percent of the metalalloy. Still another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 40-60% tin; 40-60% zinc; 0-0.4%aluminum; 0-1% antimony and/or bismuth; 0-0.001% arsenic; 0-0.01% boron;0-0.005% cadmium; 0-0.05% carbon; 0-0.05% chromium; 0-0.1% copper;0-0.05% iron; 0-0.01% lead; 0-0.01% magnesium; 0-0.01% manganese;0-0.01% molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.001% silver;0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001%vanadium; and the tin plus zinc content is at least 95 weight percent ofthe metal alloy. Still yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 45-55% zinc; 45-55% tin;0-0.4% aluminum; 0-0.8% antimony and/or bismuth; 0-0.001% arsenic;0-0.001% boron; 0-0.001% cadmium; 0-0.01% carbon; 0-0.05% copper;0-0.001% iron; 0-0.08% lead; 0-0.001% magnesium; 0-0.001% manganese;0-0.001% molybdenum; 0-0.9% nickel; 0-0.001% silicon; 0-0.005% silver;0-0.001% sulfur; 0-0.001% tellurium; 0-0.05% titanium; 0-0.001%vanadium; and the tin content plus the zinc content is at least 99% ofthe metal alloy. A further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-90% tin; 9 to 10-85%zinc; 0-0.5% aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper;0-0.4% magnesium; 0-1% nickel; 0-0.15% titanium. Yet a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-90% tin; 9 to 10-85% zinc; 0-0.3% aluminum; 0-1% antimony;0-1.7% bismuth; 0-1% copper; 0-0.4% magnesium; 0-1% nickel; 0-0.15%titanium. Still a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-80% tin; 20-85% zinc;0-0.3% aluminum; 0-1% antimony; 0-1.7% bismuth; 0-1% copper; 0-0.4%magnesium; 0-1% nickel; 0-0.15% titanium. Still yet further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-80% tin; 20-85% zinc; 0-0.5% aluminum; 0-5.5antimony; 0-1.7%bismuth; 0-2.7% copper; 0-0.4% magnesium; 0-1% nickel; and 0-0.15%titanium. Another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-70% tin; 30-85% zinc; 0-0.25%aluminum; 0-1.5% copper; 0-0.02% chromium; 0-0.01% iron; 0-0.01% lead;0-0.01% manganese; and 0-0.18% titanium. Still another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 49.75-50.25% tin; 49.75-50.25% zinc; 0-0.02% aluminum; 0-0.2%antimony; 0-0.2% arsenic; 0-0.2% copper; 0-0.025% iron; 0-0.002%palladium; and 0-0.015% titanium. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes49.5-50.5% tin; 49.5-50.5% zinc; 0.005-0.21% aluminum; 0.05-0.64%antimony; 0-0.001% arsenic; 0-0.004% bismuth; 0-0.001% cadmium;0.01-0.3% copper; 0-0.001% iron, 0-0.001% nickel; 0-0.001% silver;0.001-0.02% titanium. Still yet another and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 49.75-50.25% tin;49.75-50.25% zinc; 0-0.25% aluminum; 0-0.35% antimony; 0-0.02% arsenic;0-0.001% cadmium; 0-0.02% copper; 0-0.025% iron; 0-0.08% lead; and0-0.0175% titanium. A further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 35-70% tin; 30-65% zinc;0-5% copper; and 0-5% nickel. Yet a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-80% tin; 20-85% zinc; 0-0.1% lead. Still a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-30% tin; 70-85% zinc; and 0-0.1% lead. Yet a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-90% tin; 10-85% zinc; and 0-2% magnesium. Still yet afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 10-75% tin; 25-90% zinc; 0-0.25% aluminum;0-1.5% copper; 0-0.02% chromium; 0-0.01% iron; 0-0.01% lead; 0-0.01%manganese; and 0-0.18% titanium. Another and/or alternative formulationof the corrosion resistant tin and zinc alloy includes 15-35% tin;65-85% zinc; 0-7.5% antimony; 0-1.7% bismuth; 0-0.1% iron; and 0-0.05%lead. Yet another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 15-70% tin; 30-85% zinc; 0-7.5%antimony; 0-1.7% bismuth; 0-5% copper; 0-0.1% iron; 0-0.05% lead; and0.3-5% nickel. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 15-70% tin; 30-85% zinc;0-7.5% antimony; 0-1.7%bismuth; 0-2% copper; 0-0.1% iron; 0-0.05% lead;and 0.3-1% nickel. Still yet another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 15-70% tin; 30-85%zinc; 0.1-5% copper; and 0.3-5% nickel. A further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes35-70% tin; 30-65% zinc; 0.1-2% copper; and 0.3-1% nickel. Still afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 35-70% tin; 30-65% zinc; 0.1-1.5% copper; and0.3-0.9% nickel. A further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes at least 15% tin; zinc;and at least 0.05% antimony, bismuth and/or copper. Still a furtherformulation of the corrosion resistant tin and zinc alloy includes 9 to10-20% zinc; 0-2.5% antimony; 0-0.5% bismuth; and the remainder tin.Still a further and/or alternative formulation of the corrosionresistant tin and zinc ahoy includes 80-90% tin 9 to 10-20% zinc;0.5-1.7% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Still yeta further and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 80-90% tin; 9 to 10-20% zinc; 0.5-7.5% antimony;0-2% copper; 0-0.1% iron; and 0-0.05% lead. Another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes80-90% tin; 9 to 10-20% zinc; 0-0.5% antimony; 0-2% copper; 0-0.1% iron;and 0-0.05% lead. Still another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 80-90% tin; 9 to 10-20%zinc; 0-0.5% bismuth; 0-2% copper; 0-0.1% iron; and 0-0.05% lead. Yetanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 70-90% tin 9 to 10-30% zinc; at least 0.01%antimony. Still yet another and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 70-90% tin;9 to 10-30%zinc; 0.01-1.7% bismuth. Still another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 70-90% tin; 9to10-30% zinc; 0.1-2% iron. Yet another and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 70-90% tin; 9 to10-30% zinc; 0.1-2% copper. Still yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes amajority of tin and zinc, 0-0.5% aluminum; 0-5.5% antimony; 0-2.7%copper; and 0-0.15% titanium. A further and/or alternative formulationof the corrosion resistant tin and zinc alloy includes a majority of tinand zinc, 0-0.3% aluminum; 0-1% antimony; and 0-1% copper. Yet a furtherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 20-90% tin; 9 to 10-80% zinc; 0-1% aluminum; 0-5.5%antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.1% iron; 0-0.05% lead; 0-1%magnesium; 0-1% nickel; and 0-0.5% titanium. Still a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-80% tin; 20-80% zinc; 0-5% aluminum; 0-5.5% antimony; 0-1.5%bismuth; 0-5% copper; 0-5% magnesium; 0-5% nickel; and 0-1% titanium.Still yet a further and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 20-80% tin; 20-80% zinc; 0-0.5%aluminum; 0-5.5% antimony; 0-1.7% bismuth; 0-2.7% copper; 0-0.4%magnesium; 0-1% nickel; and 0-0.15% titanium. Still a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-80% tin; 20-80% zinc; 0-0.3% aluminum; 0-1% antimony; 0-1.7%bismuth; 0-1% copper; 0-0.4% magnesium; 0-0.7% nickel; and 0-0.15%titanium. Another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes a majority of tin and zinc, 0-0.5%aluminum; 0-2% antimony; 0-2% copper; and 0-0.15% titanium. Stillanother and/or alternative formulation of the corrosion resistant tinand zinc alloy includes a majority of tin and zinc, 0-0.3% aluminum;0-1% antimony; and 0-1% copper. Yet another and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes20-90% tin; 9 to 10-80% zinc; 0-2% aluminum; 0-2% antimony and/orbismuth; 0-2% copper; 0-1% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1%manganese; 0-1% nickel; and 0-0.15% titanium. Still yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-65% tin; 35-80% zinc; 0-2% aluminum; 0-1% antimony and/orbismuth; 0-1% copper; 0-0.6% iron; 0-0.5% lead; 0-0.4% magnesium; 0-0.1%manganese; 0-0.7% nickel; and 0-0.15% titanium. Yet another and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 20-50% tin; 50-80% zinc; 0-0.3% aluminum; 0.005-0.5% antimonyand/or bismuth; 0-0.2% copper; 0-0.6% iron; 0-0.4% lead; 0-0.4%magnesium; 0-0.05% manganese; 0-0.1% nickel; and 0-0.15% titanium. Afurther and/or alternative formulation of the corrosion resistant tinand zinc alloy includes 15-90% tin; 9 to 10-85% zinc; 0-2% aluminum;0-2% antimony; 0-1.7% bismuth; 0-2% copper; 0-1% iron; 0-1% lead; 0-2%nickel; and 0-1% titanium. Still a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes30-85% tin; 15-70% zinc; 0-1% aluminum; 0-1% antimony; 0-0.01% arsenic;0-1% bismuth; 0-0.1% cadmium; 0-0.1% chromium; 0-1% copper; 0-0.1% iron;0-0.1% lead; 0-0.01% manganese; 0-0.1% nickel; 0-0.01% silver; and0-0.05% titanium. Still yet a further and/or alternative formulation ofthe corrosion resistant tin and zinc alloy includes 50-85% tin; 15-50%zinc; 0-7.5% aluminum; 0-2% antimony; 0-0.05% arsenic; 0-0.1% boron;0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1% chromium; 0-5% copper;0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1% manganese; 0-0.1%molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1% silver; 0-0.05%tellurium; 0-0.5% titanium; and 0-0.1% vanadium. Yet a further and/oralternative formulation of the corrosion resistant tin and zinc alloyincludes 15-50% tin; 50-85% zinc; 0-7.5% aluminum; 0-2% antimony;0-0.05% arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1%carbon; 0-1% chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1%magnesium; 0-0.1% manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5%silicon; 0-0.1% silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1%vanadium. Still a further and/or alternative formulation of thecorrosion resistant tin and zinc alloy includes 20-80% tin; 20-80% zinc;0-5% aluminum; 0-7.5% antimony; 0-5% bismuth; 0-1% cadmium; 0-5% copper;0-5% nickel; and 0-0.5% titanium. Still yet a further and/or alternativeformulation of the corrosion resistant tin and zinc alloy includes15-90% tin; 9 to 10-85% zinc; 0-7.5% aluminum; 0-2% antimony; 0-0.05%arsenic; 0-0.1% boron; 0-1.7% bismuth; 0-0.5% cadmium; 0-1% carbon; 0-1%chromium; 0-5% copper; 0-1% iron; 0-10% lead; 0-1% magnesium; 0-0.1%manganese; 0-0.1% molybdenum; 0-5% nickel; 0-0.5% silicon; 0-0.1%silver; 0-0.05% tellurium; 0-0.5% titanium; and 0-0.1% vanadium. Anotherand/or alternative formulation of the corrosion resistant tin and zincalloy includes 30-70% tin; 30-70% zinc; 0-7.5% aluminum; 0-2% antimony;0-1.7% bismuth; 0-0.5% cadmium; 0-5% copper; 0-10% lead; and 0-5%nickel. Still another and/or alternative formulation of the corrosionresistant tin and zinc alloy includes 40-60% tin; 40-60% zinc; 0-2%aluminum; 0-2% antimony, bismuth, cadmium and/or copper; 0-2% lead; and0-1% nickel.

The following are several examples of tin or tin and zinc alloy beingapplied by various processes to various types of metal strip. Thefollowing examples also illustrate various ways the coated metal stripcan be formed in various types of products. The following examplesfurther illustrate the formation of the metal alloy into various typesof materials. The following examples only illustrate a few, not all,aspects of the present invention.

EXAMPLE A

A metal strip is unwound from a roll of metal strip. The metal strip hasan average thickness of about 762 microns. The metal strip iscontinuously passed through an electrolytic tank to plate nickel on thestrip surface. The nickel plated layer has a thickness of about 1-3microns. The metal alloy includes at least about 85% tin and at leastabout 9 to 10% zinc and less than about 0.5% lead. The metal alloy inthe melting pot at a temperature of about 301-455° C. The metal strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-77 microns. The coated metal strip isrewound into a roll of coated metal strip.

EXAMPLE B

A metal strip is unwound from a roll of metal strip. The metal strip hasan average thickness of about 762 microns. The metal strip is platedwith chromium of a thickness of less than about 3 microns. A metal alloyhaving a composition of at least about 45% tin, at least about 45% zinc,less than about 1% of a metal additive, and less than about 0.1% lead iscoated onto the metal strip. The metal alloy is heated in a melting potat a temperature of about 301-482° C. The strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The metal strip has a resident time in the melting pot of lessthan about 10 seconds. The coated metal strip is passed through coatingrollers and/or an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated metal strip is rewound into a roll ofcoated metal strip.

EXAMPLE C

A metal strip is unwound from a roll of metal strip. The metal strip hasan average thickness of about 762 microns. The metal strip iscontinuously plated with a tin layer of about 1-3 microns thick. A metalalloy having a composition of at least about 45% tin and at least about45% zinc is coated onto the metal strip. The metal alloy is heated in amelting pot at a temperature of about 301-482° C. The metal strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft./min. The metal strip has a resident time in themelting pot of less than about 10 seconds. The coated metal strip ispassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-77 microns. The coated metal strip isrewound into a roll of coated metal strip.

EXAMPLE D

A metal strip is unwound from a roll of metal strip and continuouslyplated with a tin layer of a thickness of less than about 3 microns. Themetal strip has an average thickness of about 762 microns. A metal alloyhaving a composition of at least about 45% tin, at least about 45% zinc,and less than about 0.1% lead is coated onto the metal strip. The metalalloy is heated in a melting pot at a temperature of about 301-427° C.The metal strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The metal strip has aresident time in the melting pot of less than about 10 seconds. Thecoated metal strip is passed through coating rollers and/or an air-knifeto achieve an average coating thickness of about 7-77 microns. Thecoated metal strip is rewound into a roll of coated metal strip.

EXAMPLE E

A metal strip is unwound from a roll of metal strip. The metal strip iscontinuously plated with a tin layer of about 1-3 microns thick. Themetal strip has an average thickness of about 762 microns. A metal alloyhaving a composition of at least about 20% tin, and at least about 75%zinc and is heated in a melting pot at a temperature of about 301-427°C. The metal strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The metal strip has aresident time in the melting pot of less than about 10 seconds. Thecoated metal strip is passed through coating rollers and/or an air-knifeto achieve an average coating thickness of about 7-77 microns. Thecoated metal strip is rewound into a roll of coated metal strip.

EXAMPLE F

A metal strip is unwound from a roll of metal strip and is pickled witha hydrochloric acid solution and a copper sulfate solution. Copper isplated onto the metal strip surface during the pickling process forminga copper layer of about 1-3 microns thick. The metal strip has anaverage thickness of about 762 microns. The metal alloy includes atleast about 70% tin, at least about 25% zinc, and less than about 0.2%lead. The metal alloy in the melting pot is heated to a temperature ofabout 301-482° C. The metal strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Themetal strip has a resident time in the melting pot of less than about 10seconds. The coated metal strip is passed through coating rollers and/oran air-knife to achieve an average coating thickness of about 7-77microns. The coated metal strip is rewound into a roll of coated metalstrip.

EXAMPLE G

A metal strip is unwound from a roll of metal strip and is pickled witha hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating the metal alloy. The metal strip hasan average thickness of about 762 microns. The metal strip is notpre-heated prior to coating. A tin alloy having a composition of about90-99% tin and less than about 2% lead is coated onto the metal strip.The tin alloy in the melting pot is heated to at least above 238-246° C.The metal strip is passed through the melting pot at a speed of about100 ft/min. The metal strip has a resident time in the melting pot ofless than about 10 seconds. The coated metal strip is passed throughcoating rollers and/or an air knife to achieve an average coatingthickness of about 7-51 microns. The coated metal strip is then cooled.The coated metal strip is then oxidized to remove the coated tin alloyand to expose and passify the heat created intermetallic layer. Themetal strip is then wound into a roll of the metal strip.

EXAMPLE H

A metal strip is unwound from a roll of metal strip and is pickled witha hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating. The metal strip has an averagethickness of about 762 microns. The metal strip is plated with nickelhaving a thickness of less than about 3 microns. The metal strip ispreheated prior to coating. A tin alloy having a composition of above90-99% tin and less than about 2% lead is coated onto the metal strip.The metal alloy is heated in a melting pot to a temperature of about238-482° C. The metal strip is passed through the melting pot at a speedof about 100 ft/min. The metal strip has a resident time in the meltingpot of less than about 10 seconds. The coated metal strip is passedthrough coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-51 microns. The coated metal strip iscooled and then oxidized to remove the tin alloy to expose and passifythe heat created intermetallic layer. The metal strip is then wound intoa roll of metal strip.

EXAMPLE I

A metal strip is unwound from a roll of metal strip. The metal strip hasan average thickness of about 762 microns. The metal strip is notpre-heated prior to coating with a metal alloy. A tin alloy having acomposition of about 90-99% tin, and less than about 0-5% lead is coatedonto the metal strip. The tin alloy is applied to the metal strip by anelectroplating process. The plated metal strip is then flow heated forless than about 5 minutes. The coated metal strip is then passed throughcoating rollers and/or an air-knife to achieve an average coatingthickness of about 7-51 microns. The coated metal strip is then cooled.The coated metal strip is then oxidized to remove the tin alloy and toexpose and passify the heat created intermetallic layer. The metal stripis then wound into a roll of metal strip.

EXAMPLE J

A metal strip is unwound from a roll of metal strip and plated with azinc layer having a thickness of less than about 3 microns. The metalstrip has an average thickness of about 762 microns. The metal strip ispre-heated prior to coating with a metal alloy. A tin alloy having acomposition of about 90-99% tin and less than about 0-1% lead is coatedonto the metal strip. The metal strip is passed through a metal spayingprocess at a speed of up to about 100 ft/min to coat the metal strip.The coated metal strip is then passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-51 microns.The coated metal strip is cooled and then oxidized to remove the tinalloy and to expose and passify the heat created intermetallic layer.The metal strip is then cut into metal sheets.

EXAMPLE K

A metal strip is unwound from a roll of metal strip and is pickled withan acid solution and then chemically activated with a chemicalactivation solution. The metal strip is then plated with a metal layerof about 1-3 microns thick. The metal strip is not pre-heated prior tocoating with a metal alloy. A tin alloy having a composition of about90-99% tin is coated onto the metal strip. The tin alloy is plated ontothe metal strip and then flow heated. The metal strip is then coatedagain by a spray metal process. The coated metal strip is then passedthrough coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-51 microns. The coated metal strip is thencooled and wound into a roll of coated metal strip. The roll of coatedmetal strip is formed into roofing materials and installed on abuilding. The formed coated metal strip is then exposed to an oxidizingsolution on site to remove the tin alloy and expose and passify the heatcreated intermetallic layer.

EXAMPLE L

A carbon steel strip is unwound from a roll of carbon steel strip. Thecarbon steel strip has an average thickness of about 762 microns. Thecarbon steel strip is continuously passed through an electrolytic tankto plate nickel on the carbon steel strip surface. The nickel platedlayer has a thickness of about 1-3 microns. A metal alloy having acomposition of at least about 95% tin and zinc, and less than about 0.5%lead is coated onto the carbon steel strip. The metal alloy in themelting pot is at a temperature of about 301-455° C. The carbon steelstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The carbon steel strip has a residenttime in the melting pot of less than about 10 seconds. The coated carbonsteel strip is passed through coating rollers and/or an air-knife toachieve an average coating thickness of about 7-77 microns. The coatedcarbon steel strip is rewound into a roll of coated carbon steel strip.

EXAMPLE M

A carbon steel strip is unwound from a roll of carbon steel strip. Thecarbon steel strip has an average thickness of about 762 microns. Thecarbon steel strip is plated with chromium of a thickness of less thanabout 3 microns. A metal alloy having a composition of at least about98% tin and zinc, less than about 1% of a metal additive, less thanabout 0.1% lead is coated onto the carbon steel strip. The metal alloyis heated in a melting pot at a temperature of about 301-482° C. Thecarbon steel strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The carbon steel strip hasa resident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-77 microns.The coated carbon steel strip is rewound into a roll of coated carbonsteel strip.

EXAMPLE N

A copper strip is unwound from a roll of copper strip. The copper striphas an average thickness of about 762 microns. The copper strip iscontinuously plated with a tin layer of about 1-3 microns thick. A metalalloy having a composition of at least about 99% tin and zinc is coatedonto the copper strip. The metal alloy is heated in a melting pot at atemperature of about 301-482° C. The coated strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft./min. The copper strip has a resident time in the melting pot of lessthan about 10 seconds. The coated copper strip is passed through coatingrollers and/or an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated copper strip is rewound into a roll ofcoated copper strip.

EXAMPLE O

A carbon steel strip is unwound from a roll of carbon steel strip andcontinuously plated with a tin layer of a thickness of less than about 3microns. The carbon steel strip has an average thickness of about 762microns. A metal alloy having a composition of at least about 98% tinand zinc, and less than about 0.1% lead is coated onto the carbon steelstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-427° C. The carbon steel strip is passed through the meltingpot having a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve an average coatingthickness of about 7-77 microns. The coated carbon steel strip isrewound into a roll of coated carbon steel strip.

EXAMPLE P

A stainless steel strip is unwound from a roll of stainless steel strip.The stainless steel strip is continuously plated with a tin layer ofabout 1-3 microns thick. The stainless steel strip has an averagethickness of about 762 microns. A metal alloy having a composition of atleast about 98-99% tin and zinc is heated in a melting pot at atemperature of about 301-427° C. The stainless steel strip is passedthrough the melting pot having a length of about 16 feet at a speed ofabout 100 ft/min. The stainless steel strip has a resident time in themelting pot of less than about 10 seconds. The coated stainless steelstrip is passed through coating rollers and/or an air-knife to achievean average coating thickness of about 7-77 microns. The coated stainlesssteel strip is rewound into a roll of coated stainless steel strip.

EXAMPLE Q

A carbon steel strip is unwound from a roll of carbon steel strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the carbon steel strip surface during the picklingprocess to form a copper layer of about 1-3 microns thick. The carbonsteel strip has an average thickness of about 762 microns. A metal alloyhaving a composition of at least about 95-99% tin and zinc, and lessthan about 0.2% lead is coated onto the carbon steel strip. The metal ina melting pot is heated to a temperature of about 301-482° C. The carbonsteel strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The carbon steel strip has aresident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-77 microns.The coated carbon steel strip is rewound into a roll of coated carbonsteel strip.

EXAMPLE R

A carbon steel strip is unwound from a roll of carbon steel strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The carbon steel strip has anaverage thickness of about 762 microns. The carbon steel strip is notpre-heated prior to coating. A metal alloy having a composition of about90-95% tin, and less than about 0.5% lead is coated onto the carbonsteel strip. The metal alloy in the melting pot is heated to atemperature of about 238-246° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecarbon steel strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The carbon steel strip hasa resident time in the melting pot of less than about 10 seconds. Thecoated carbon steel is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-51 microns.The coated carbon steel strip is then cooled and rewound into a roll ofcoated carbon steel strip.

EXAMPLE S

A carbon steel strip is unwound from a roll of carbon steel strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The carbon steel strip has anaverage thickness of about 762 microns. The carbon steel strip is platedwith chromium of a thickness of less than about 3 microns. The carbonsteel strip is not pre-heated prior to coating. A metal alloy having acomposition of about 90-99% tin, about 0.01-1% metallic stabilizerselected from antimony, bismuth and/or copper, and less than about 0.5%lead is coated onto the carbon steel strip. The metal alloy is heated ina melting pot at a temperature of about 238-482° C. The melting pot isheated by four external gas torches directed to the outer sides of themelting pot. The carbon steel strip is passed through the melting pothaving a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve an average coatingthickness of about 7-51 microns. The coated carbon steel strip is thencooled and rewound into a roll of coated carbon steel strip.

EXAMPLE T

A copper strip is unwound from a roll of copper strip and is pickledwith a hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating. The copper strip has an averagethickness of about 762 microns. The copper strip is not pre-heated priorto coating. A metal alloy having a composition of about 90-99% tin, 0-1%metallic stabilizer, and less than about 0.1% lead is coated onto thecopper strip. The metal alloy is heated in a melting pot at atemperature of about 238-246° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecopper strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft./min. The copper strip has a residenttime in the melting pot of less than about 10 seconds. The coated copperstrip is passed through coating rollers and/or an air-knife to achievean average coating thickness of about 7-51 microns. The coated copperstrip is then cooled and rewound into a roll of coated copper strip.

EXAMPLE U

A carbon steel strip is unwound from a roll of carbon steel strip andplated with a nickel layer of a thickness of less than about 3 microns.The carbon steel strip has an average thickness of about 762 microns.The carbon steel strip is not pre-heated prior to coating. A metal alloyhaving a composition of about 90-99% tin, and less than about 0.1% leadis coated onto the carbon steel strip. The metal ahoy is heated in amelting pot at a temperature of about 238-255° C. The melting pot isheated by four external gas torches directed to the outer sides of themelting pot. The carbon steel strip is passed through the coating tankhaving a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel strip has a resident time in the melting pot of less thanabout 10 seconds. The coated carbon steel strip is passed throughcoating rollers and/or an air-knife to achieve an average coatingthickness of 7-51 microns. The coated carbon steel strip is then cooledand rewound into a roll of coated carbon steel strip.

EXAMPLE V

A stainless steel strip is unwound from a roll of stainless steel stripand is aggressively pickled with a dual acid solution of hydrochloricacid and nitric acid and chemically activated with a zinc chloridesolution. The stainless steel strip is plated with a nickel layer ofabout 1-3 microns thick. The stainless steel strip has an averagethickness of about 762 microns. The stainless steel strip is notpre-heated prior to coating. A metal alloy having a composition of about90-99% tin and is heated in a melting pot at a temperature of about238-260° C. The melting pot is heated by four external gas torchesdirected to the outer sides of the melting pot. The stainless steelstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The stainless steel strip has a residenttime in the melting pot of less than about 10 seconds. The coatedstainless steel strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-51 microns.The coated stainless steel strip is then cooled and rewound into a rollof coated stainless steel strip.

EXAMPLE W

A carbon steel strip is unwound from a roll of carbon steel strip and ispickled with a hydrochloric acid solution and a copper sulfate solutionand chemically activated with a zinc chloride solution prior to coating.Copper is plated onto the carbon steel strip surface during the picklingprocess to form a copper layer of about 1-3 microns thick. The carbonsteel strip has an average thickness of about 762 microns. The carbonsteel strip is not pre-heated prior to coating. A metal alloy having acomposition of about 90-95% tin and less than about 0.5% lead is coatedonto the carbon steel strip. The metal alloy is heated in a melting potat a temperature of about 238-250° C. The melting pot is heated by fourexternal gas torches directed to the outer sides of the melting pot. Thecarbon steel strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The carbon steel strip hasa resident time in the melting pot of less than about 10 seconds. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-51 microns.The coated carbon steel strip is then cooled and rewound into a roll ofcoated carbon steel strip.

EXAMPLE X

A carbon steel strip is unwound from a roll of carbon steel strip and ispickled with a hydrochloric acid solution and chemically activated witha zinc chloride solution prior to coating. The carbon steel strip has anaverage thickness of more than about 762 microns. The carbon steel stripis pre-heated prior to coating. A metal alloy having a composition ofabout 90-99% tin and less than about 0.1% lead is coated onto the carbonsteel strip. The metal alloy is heated in a melting pot at a temperatureof about 237-246° C. The melting pot is heated by four external gastorches directed to the outer sides of the melting pot. The carbon steelstrip is passed through the melting pot having a length of about 16 feetat a speed of about 100 ft/min. The carbon steel strip has a residenttime in the melting pot of less than about 10 seconds. The coated carbonsteel strip is passed through coating rollers and/or an air-knife toachieve an average coating thickness of about 7-51 microns. The coatedcarbon steel strip is then cooled and rewound into a roll of coatedcarbon steel strip.

EXAMPLE Y

A thin strip of carbon steel uncoiled from a roll of carbon steel ispassed through an electroplating bath to deposit an ultra thin layer oftin on the carbon steel strip. The carbon steel strip has an averagethickness of about 762 microns. The carbon steel strip is then coatedwith a two-phase zinc-tin coating to produce an intermetallic layerbetween the metal alloy and the carbon steel strip. The tin-zinc alloyhas a coating of tin and zinc content at least about 75 weight percent.

EXAMPLE Z

The process of Example Y was preformed with the addition of a heatingfurnace to flow heat the thin tin plating and, thus, form a heat createdintermetallic layer including iron and tin prior to the metal alloycoating process.

EXAMPLE AA

The process of Example Y was preformed with copper being plated on thecarbon steel strip by an electrolytic bath.

EXAMPLE BB

A copper strip is unwound from a roll of copper strip. The copper striphas an average thickness of about 762 microns. The copper strip ispickled with an acid to clean the surface of the copper strip. Thecopper strip is continuously passed through an electrolytic tank toplate nickel on the copper strip surface. The nickel plated layer has athickness of about 1-3 microns. The copper strip is no preheated. Ametal alloy having a composition of at least about 95% tin and zinc, andless than about 0.5% lead is coated onto the copper strip. The metalalloy is in a melting pot at a temperature of about 301-454° C. Thecopper strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The copper strip has a residenttime in the melting pot of less than about 10 seconds. The coated copperstrip is passed through coating rollers and/or an air-knife to achievean average coating thickness of about 7-77 microns. The coated copperstrip is rewound into a roll of coated copper strip.

EXAMPLE CC

A brass strip is unwound from a roll of brass strip. The brass strip hasan average thickness of about 762 microns. The brass strip is pickled toremove surface oxides. The brass strip is plated with chromium having athickness of less than about 3 microns. The brass strip is notpreheated. A metal alloy having a composition of at least about 98% tinand zinc, less than about 1% of a metal additive, and less than about0.1% lead is coated onto the brass strip. The metal alloy is heated in amelting pot at a temperature of about 301-482° C. The brass strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The brass strip has a resident time in themelting pot of less than about 10 seconds. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-77 microns. The coated brass strip isrewound into a roll of coated brass strip.

EXAMPLE DD

A bronze strip is unwound from a roll of bronze strip. The bronze striphas an average thickness of about 762 microns. The copper strip iscontinuously plated with a tin layer of about 1-3 microns thick. A metalalloy having a composition of at least about 99% tin and zinc is coatedonto the bronze strip. The metal alloy is heated in a melting pot at atemperature of about 301-482° C. The bronze strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft./min. The bronze strip has a resident time in the melting pot of lessthan about 10 seconds. The coated bronze strip is passed through coatingrollers and/or an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated bronze strip is rewound into a roll ofcoated bronze strip.

EXAMPLE EE

A carbon steel strip is unwound from a roll of carbon steel strip andcontinuously plated with a tin layer of an average thickness of about 3microns. The carbon steel strip has a thickness of less than 762microns. A metal alloy having a composition of at least about 98% tinand zinc, and less than about 0.1% lead is coated onto the carbon steelstrip. The metal alloy is plated and subsequently flow heated onto thesurface of the carbon steel strip. The coated carbon steel strip ispassed through an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated carbon steel strip is oxidized to exposethe heat created intermetallic layer. The oxidized carbon steel strip isrewound into a roll of oxidized carbon steel strip.

EXAMPLE FF

A stainless steel strip is unwound from a roll of stainless steel strip.The stainless steel strip is aggressively pickled and chemicallyactivated to clean the stainless steel strip surface. The stainlesssteel strip is continuously plated with a tin layer of about 1-3 micronsthick. The stainless steel strip has an average thickness of about 762microns. The stainless steel strip is preheated. A metal alloy having acomposition of at least about 98-99% tin and zinc is heated in a meltingpot at a temperature of about 301-427° C. The stainless steel strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The stainless steel strip has a resident timein the melting pot of less than about 10 seconds. The coated stainlesssteel strip is passed through coating rollers and/or an air-knife toachieve an average coating thickness of about 7-77 microns. The coatedstainless steel strip is oxidized to expose the heat createdintermetallic layer. The oxidized stainless steel strip is rewound intoa roll of oxidized stainless steel strip.

EXAMPLE GG

A carbon steel strip is unwound from a roll of carbon steel strip and ispickled with a hydrochloric acid solution and a copper sulfate solution.Copper is plated onto the carbon steel strip surface during pickling toform a copper layer of about 1-3 microns thick. The carbon steel striphas an average thickness of about 762 microns. A metal alloy having acomposition of at least about 95-99% tin and zinc, and less than about0.2% lead is coated onto the carbon steel strip. The metal alloy isplated and subsequently flow heated onto the carbon steel strip. Thecoated carbon steel strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-77 microns.The coated carbon steel strip is rewound into a roll of coated carbonsteel strip.

EXAMPLE HH

A brass strip is unwound from a roll of brass strip. The brass strip hasan average thickness of about 762 microns. The brass is continuouslypassed through an electrolytic tank to plate nickel on the brass stripsurface. The nickel plated layer has a thickness of about 1-3 microns. Ametal alloy having a composition of 95-98% tin and zinc, and less thanabout 0.5% lead is coated onto the brass strip. The metal alloy in amelting pot is heated to a temperature of about 301-455° C. The carbonsteel strip is passed through the melting pot having a length of about16 feet at a speed of about 100 ft/min. The brass strip has a residenttime in the melting pot of less than about 10 seconds. The coated brassstrip is passed through coating rollers and/or an air-knife to achievean average coating thickness of about 7-77 microns. The coated brassstrip is rewound into a roll of coated brass strip.

EXAMPLE II

A tin strip is unwound from a roll of tin strip. The tin strip has anaverage thickness of about 762 microns. The tin strip is plated withchromium of a thickness of less than about 3 microns. A metal alloyhaving a composition of about 95-98% tin and zinc, less than about 2% ofa metal additive, and less than about 0.5% lead is coated onto the tinstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-482° C. The tin strip is passed through the melting pot havinga length of about 16 feet at a speed of about 100 ft/min. The tin striphas a resident time in the melting pot of less than about 10 seconds.The coated tin strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-77 microns.The coated tin strip is rewound into a roll of coated tin strip.

EXAMPLE JJ

A copper strip is unwound from a roll of copper strip. The copper striphas an average thickness of about 762 microns. The copper strip iscontinuously plated with a tin layer of about 1-3 microns thick. A metalalloy having a composition of about 90-99% tin and 0-5% lead is coatedonto the copper strip. The metal alloy is heated in a melting pot at atemperature of about 301-482° C. The copper strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft./min. The copper strip has a resident time in the melting pot of lessthan about 10 seconds. The coated copper strip is passed through coatingrollers and/or an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated copper strip is rewound into a roll ofcoated copper strip.

EXAMPLE KK

A carbon steel strip is unwound from a roll of carbon steel strip andcontinuously plated with a tin layer of an average thickness of about 3microns. The carbon steel strip has a thickness of less than about 762microns. A metal alloy having a composition of about 90-99% tin andzinc, and less than about 0.5% lead is coated onto the carbon steelstrip. The metal alloy is heated in a melting pot at a temperature ofabout 301-482° C. The carbon steel strip is passed through the meltingpot having a length of about 16 feet at a speed of about 100 ft/min. Thecarbon steel has a resident time in the melting pot of less than about10 seconds. The coated carbon steel strip is passed through coatingrollers and/or an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated carbon steel strip is rewound into a rollof coated carbon steel strip.

EXAMPLE LL

A stainless steel strip is unwound from a roll of stainless steel strip.The stainless steel strip is continuously plated with a tin layer ofabout 1-3 microns thick. The stainless steel strip has an averagethickness of about 762 microns. A metal alloy having a composition ofabout 90-99% tin and zinc is heated in a melting pot at a temperature ofabout 301-482° C. The stainless steel strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The stainless steel strip has a resident time in the melting potof less than about 10 seconds. The coated stainless steel strip ispassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-77 microns. The coated stainless steelstrip is rewound into a roll of coated stainless steel strip.

EXAMPLE MM

A brass strip is unwound from a roll of brass strip and is pickled witha hydrochloric acid solution and a copper sulfate solution. Copper isplated onto the carbon steel strip surface during pickling to form acopper layer of about 1-3 microns thick. The brass strip has an averagethickness of 762 microns. A metal alloy having a composition of about90-95% tin, and less than about 0.5% lead is heated in a melting pot ata temperature of about 301-482° C. The brass strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The brass strip has a resident time in the melting pot of lessthan about 10 seconds. The coated brass strip is passed through coatingrollers and/or an air-knife to achieve an average coating thickness ofabout 7-77 microns. The coated brass strip is rewound into a roll ofcoated brass strip.

EXAMPLE NN

A copper strip is unwound from a roll of copper strip and is pickledwith a hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating. The copper strip has an averagethickness of about 762 microns. The copper strip is not pre-heated priorto coating. A tin alloy having a composition of about 90-99% tin, andless than about 2% lead is heated in a melting pot at a temperature ofabout 237-246° C. The copper strip is passed through the melting pot ata speed of about 100 ft/min. The copper strip has a resident time in thecoating tank of less than about 10 seconds. The coated copper strip ispassed through coating rollers and/or an air knife to achieve an averagecoating thickness of about 7-51 microns. The coated copper strip is thencooled. The coated copper strip is then oxidized to remove the coatedtin alloy and to expose and pacify the heat created intermetallic layer.The copper strip is then wound into a roll of copper strip.

EXAMPLE OO

A copper strip is unwound from a roll of copper strip and is pickledwith a hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating. The copper strip has an averagethickness of about 762 microns. The copper strip is plated with nickelhaving a thickness of less than about 3 microns. The copper strip ispreheated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-482° C. The copper strip is passed through themelting pot at a speed of about 100 ft./min. The copper strip has aresident time in the melting pot of less than about 10 seconds. Thecoated copper strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 7-51 microns.The coated copper strip is cooled and then oxidized to remove the tinalloy and to expose and pacify the heat created intermetallic layer. Thecopper strip is then wound into a roll of copper strip.

EXAMPLE PP

A copper strip is unwound from a roll of copper strip. The copper striphas an average thickness of about 762 microns. The strip is notpre-heated prior to coating. A tin alloy having a composition of about99% tin, and less than about 0-5% lead is applied to the copper strip byan electroplating process. The plated copper strip is then flow heatedfor less than about 5 minutes. The coated copper strip is passed throughcoating rollers and/or an air-knife to achieve an average coatingthickness of about 7-51 microns. The coated copper strip is then cooled.The coated copper strip is then oxidized to remove the tin alloy and toexpose and pacify the heat created intermetallic layer. The copper stripis then wound into a roll of copper strip.

EXAMPLE QQ

A copper steel strip is unwound from a roll of copper strip and platedwith a chromium layer having a thickness of less than about 3 microns.The copper strip has an average thickness of about 762 microns. Thecopper strip is pre-heated prior to coating. A tin alloy having acomposition of about 90-99% tin, and less than about 0-1% lead is coatedonto the copper strip. The copper strip is passed through a metalspaying process at a speed of up to about 100 ft/min. The coated copperstrip is then passed through coating rollers and/or an air-knife toachieve an average coating thickness of about 7-51 microns. The coatedcopper strip is cooled and then oxidized to remove the tin alloy toexpose and pacify the heat created intermetallic layer. The copper stripis then cut into sheets.

EXAMPLE RR

A copper strip is unwound from a roll of copper strip and is pickledwith an acid solution and then chemically activated with a chemicalactivation solution. The copper strip is plated with a metal layer ofabout 1-3 microns thick. The copper strip is not pre-heated prior tocoating. A tin alloy having a composition of about 90-99% tin is metalsprayed onto the copper strip. The coated copper strip is then passedthrough coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-51 microns. The coated copper strip is thencooled and wound into a roll of copper strip. The roll of coated copperstrip is later formed into roofing materials and installed on abuilding. The formed coated copper strip is then exposed on site to anoxidizing solution to remove the tin alloy and expose and pacify theintermetallic layer.

EXAMPLE SS

A tin strip is unwound from a roll of tin strip. The tin strip has anaverage thickness of about 762 microns. The tin strip is continuouslypassed through an electrolytic tank to plate nickel on the tin stripsurface. The nickel plated layer has a thickness of about 1-3 microns. Ametal alloy having a composition of at least about 85% tin, at leastabout 9 to 10% zinc, and less than about 0.5% lead is heated in amelting pot at a temperature of about 301-455° C. The tin strip ispassed through the melting pot having a length of about 16 feet at aspeed of about 100 ft/min. The tin strip has a resident time in themelting pot of less than about 10 seconds. The coated tin strip ispassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-77 microns. The coated tin strip is rewoundinto a roll of coated tin strip.

EXAMPLE TT

A bronze strip is unwound from a roll of bronze strip. The bronze striphas an average thickness of about 762 microns. The bronze strip isplated with chromium of a thickness of less than about 3 microns. Ametal alloy having a composition of at least about 45% tin, at leastabout 45% zinc, less than about 1% of a metal additive, and less thanabout 0.1% lead is heated in a melting pot at a temperature of about301-482° C. The bronze strip is passed through the melting pot having alength of about 16 feet at a speed of about 100 fill-in. The bronzestrip has a resident time in the melting pot of less than about 10seconds. The coated bronze strip is passed through coating rollersand/or an air-knife to achieve an average coating thickness of about7-77 microns. The coated bronze strip is rewound into a roll of coatedbronze strip.

EXAMPLE UU

An aluminum strip is unwound from a roll of aluminum strip. The aluminumstrip has an average thickness of about 762 microns. The aluminum stripis continuously plated with a tin layer of about 1-3 microns thick. Ametal alloy having a composition of at least about 45% tin and at leastabout 45% zinc is heated in a melting pot at a temperature of about301-482° C. The aluminum strip is passed through the melting pot havinga length of about 16 feet at a speed of about 100 ft./min. The aluminumstrip has a resident time in the melting pot of less than about 10seconds. The coated aluminum strip is passed through coating rollersand/or an air-knife to achieve an average coating thickness of about7-77 microns. The coated aluminum strip is rewound into a roll of coatedaluminum strip.

EXAMPLE VV

A tin strip is unwound from a roll of tin strip and continuously platedwith a tin layer of a thickness of less than about 3 microns. The tinstrip has an average thickness of about 762 microns. A metal alloyhaving a composition of at least about 45% tin, at least about 45% zinc,and less than about 0.1% lead is heated in a melting pot at atemperature of about 301-427° C. The tin strip is passed through themelting pot having a length of about 16 feet at a speed of about 100ft/min. The tin has a resident time in the melting pot of less thanabout 10 seconds. The coated tin strip is passed through coating rollersand/or an air-knife to achieve an average coating thickness of about7-77 microns. The coated tin strip is rewound into a roll of coated tinstrip.

EXAMPLE WW

A brass strip is unwound from a roll of brass strip. The brass strip iscontinuously plated with a tin layer of about 1-3 microns thick. Thebrass strip has an average thickness of about 762 microns. A metal alloyhaving a composition of at least about 20% tin, and at least about 75%zinc is heated in a melting pot at a temperature of about 301-427° C.The brass strip is passed through the melting pot having a length ofabout 16 feet at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air-knifeto achieve an average coating thickness of about 7-77 microns. Thecoated brass strip is rewound into a roll of coated brass strip.

EXAMPLE XX

A brass strip is unwound from a rail of brass strip and is pickled witha hydrochloric acid solution and a copper sulfate solution. Copper isplated onto the brass strip surface during pickling to form a copperlayer of about 1-3 microns thick. The brass strip has an averagethickness of about 762 microns. A metal alloy having a composition of atleast about 70% tin, at least about 25% zinc, and less than about 0.2%lead is heated in a melting pot at a temperature of about 301-482° C.The brass strip is coated by metal strap jets. The coated brass strip ispassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-77 microns. The coated brass strip isrewound into a roll of coated brass strip.

EXAMPLE YY

A brass strip is unwound from a roll of brass strip and is pickled witha hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating. The brass strip has an averagethickness of about 762 microns. The brass strip is not pre-heated priorto coating. A tin alloy having a composition of about 90-99% tin, andless than about 2% lead is heated in a melting pot at a temperature ofabout 237-246° C. The brass strip is passed through the melting pot at aspeed of about 100 ft/min. The brass strip has a resident time in themelting pot of less than about 10 seconds. The coated brass strip ispassed through coating rollers and/or an air knife to achieve an averagecoating thickness of about 7-51 microns. The coated brass strip is thencooled. The coated brass strip is then oxidized to remove the coated tinalloy to expose and pacify the heat created intermetallic layer. Thebrass strip is then wound into a roll of brass strip.

EXAMPLE ZZ

A brass strip is unwound from a roll of brass strip and is pickled witha hydrochloric acid solution and chemically activated with a zincchloride solution prior to coating. The brass strip has an averagethickness of about 762 microns. The brass strip is plated with nickelhaving a thickness of less than about 3 microns. The brass strip ispreheated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 2% lead is heated in a melting pot at atemperature of about 237-482° C. The brass strip is passed through themelting pot at a speed of about 100 ft/min. The brass strip has aresident time in the melting pot of less than about 10 seconds. Thecoated brass strip is passed through coating rollers and/or an air-knifeto achieve an average coating thickness of about 7-51 microns. Thecoated brass strip is cooled and then oxidized to remove the tin alloyto expose and pacify the heat created intermetallic layer. The brassstrip is then wound into a roll of brass strip.

EXAMPLE AAA

A brass strip is unwound from a roll of brass strip. The brass strip hasan average thickness of about 762 microns. The brass strip is pickled toclean the brass strip surface. The brass strip is not pre-heated priorto coating. A tin alloy having a composition of about 99% tin, and lessthan about 0-5% lead is applied to the brass strip by an electroplatingprocess. The plated brass strip is then flow heated for less than about5 minutes. The coated brass strip is passed through coating rollersand/or an air-knife to achieve an average coating thickness of about7-51 microns. The coated brass strip is then cooled. The coated brassstrip is then oxidized to remove the tin alloy and to expose and pacifythe heat created intermetallic layer. The brass strip is then wound intoa roll of brass strip.

EXAMPLE BBB

A brass strip is unwound from a roll of brass strip and plated with azinc layer having an average thickness of about 3 microns. The brassstrip has a thickness of less than about 762 microns. The brass strip ispre-heated prior to coating. A tin alloy having a composition of about90-99% tin, and less than about 0-1% lead is passed through a metalspaying process at a speed of up to 100 ft/min. The coated brass stripis then passed through coating rollers and/or an air-knife to achieve anaverage coating thickness of about 7-51 microns. The coated brass stripis cooled and then oxidized to remove the tin alloy and to expose andpacify the heat created intermetallic layer. The brass strip is then cutinto sheets.

EXAMPLE CCC

A brass strip is unwound from a roll of brass strip and is pickled withan acid solution and then chemically activated with a chemicalactivation solution. The brass strip is plated with a metal layer ofabout 1-3 microns thick. The brass strip is not pre-heated prior tocoating. A tin alloy having a composition of about 90-99% tin is platedonto the brass strip and then flow heated. The brass strip is thencoated again by a spray metal process. The coated brass strip is thenpassed through coating rollers and/or an air-knife to achieve an averagecoating thickness of about 7-51 microns. The coated brass strip is thencooled and wound into a roll of brass strip. The roll of coated brassstrip is formed into roofing materials and installed on a building. Theformed coated strip is then exposed on site to an oxidizing solution toremove the tin alloy and to expose and to pacify the intermetalliclayer.

EXAMPLE DDD

A copper metal strip is unwound from a roll of copper metal strip. Thecopper metal strip has an average thickness of about 762 microns. Ametal alloy having a composition of about 40-60% tin and about 40-60%zinc is coated onto the copper metal strip. The copper metal strip ispassed through the melting pot having a length of at least about 5 feetat a speed of about 20-100 ft./min. The copper metal strip has aresident time in the melting pot of less than about 100 seconds. Thecoated copper metal strip is passed through coating rollers and/or anair-knife to achieve an average coating thickness of about 3-77 microns.FIG. 22 illustrates the copper base metal 300 coated with the tin andzinc alloy 320. A heat created intermetallic layer 310 is alsoillustrated between tin and zinc alloy 320 and copper base metal 300. Asbest illustrated in FIG. 23, the thickness of the intermetallic layerand the tin and zinc alloy are about the same. The thickness of each ofthese layers is less than about 10 microns, and typically about 4-8microns. As such, the total thickness of the heat created intermetalliclayer plus the tin and zinc alloy is about 3-20 microns, and typically8-16 microns. As can be appreciated, the residence time of the coppermetal strip in the melting pot can be selected to created thicker orthinner layers. The thickness of the copper metal strip illustrated inFIG. 22 is about 200-600 microns and typically about 240-480 microns. Ascan be appreciated, thicker or thinner copper metal strip can be used. Aunique phenomena was discovered when analyzing the composition of thetin and zinc top coating and the heat created intermetallic layer. Asillustrated by the graphs in FIG. 23, the composition of heat createdintermetallic layer is principally copper and zinc. The graphillustrates that little, if any, tin is included in the heat createdintermetallic layer 310. Apparently, the molten tin in the tin and zincalloy has significantly less affinity than the zinc to combine with thecopper in the heated interface between the copper metal strip and themolten tin and zinc. The zinc appears to have partially migrated fromthe tin and zinc alloy and into the copper to form a copper-zinc heatcreated intermetallic layer. The composition of the tin and zinc layer320 is also interesting at the interface with the heat createdintermetallic layer. Upon crossing the interface into the tin and zincalloy coating, little, if any, copper is present in the tin and zincalloy coating. The distribution of the zinc in the tin for the tin andzinc coating was also interesting. The tin and zinc layer was found tobe porous and include scattered small fingers of zinc penetratingthrough the tin to the surface of the tin and zinc coating. The reasonsfor these phenomena are presently not known to the inventors. The coatedcopper metal strip was subjected to various types of environments. Theresults of these tests revealed that the bonding of the tin and zincalloy to the copper metal strip was very strong, thus exhibited little,if any, flaking. The teats also revealed that the coated copper metalstrip had excellent corrosion resistant properties. In environments thatexposed the coated copper metal strip to water, the coated copper metalstrip exhibited excellent corrosion resistant properties. Applicantsbelieve that the formation of the copper and zinc heat createdintermetallic layer is facilitated by the fact that the zinc content inthe tin and zinc alloy is above the eutectic point of the tin and zincalloy. As such, the globules of zinc in the tin and zinc alloy are ablethe combine with the copper to form the copper and zinc heat createdintermetallic layer. As such, tin and zinc coatings that include atleast 9 to 10 weight percent zinc readily form a copper and zinc heatcreated intermetallic layer when such a tin and zinc alloy is coated onthe copper metal strip. Copper metal strip that is coated with a tinalloy that includes less than 9 to 10 weight percent zinc will form acopper and zinc heat created intermetallic layer to a lesser degree.When using a tin alloy coating, the zinc content should be at leastabout 5 to 10 weight percent of the coating so as to form a significantcopper-zinc heat created intermetallic layer. The formation of thehighly corrosion resistant copper and zinc intermetallic layer will bepresent in copper alloy metal strip that is coated with a tin and zincalloy or tin alloy having a significant amount of zinc (e.g., at leastabout 5 weight percent), and also in a non-copper or non-copper alloymetal strip that has been plated, clad, brazened, hot dipped, etc. witha copper or copper alloy layer and then coated with a tin and zinc alloyor tin alloy having a significant amount of zinc.

EXAMPLE EEE

A carbon steel metal strip is unwound from a roll of carbon steel metalstrip. The carbon steel metal strip has an average thickness of about762 microns. The carbon steel strip is plated with a copper layer ofabout 1-6 microns thick. A metal ahoy having a composition of about40-60% tin and about 40-60% zinc is coated onto the carbon steel metalstrip. The carbon steel metal strip is passed through the melting pothaving a length of at least about 5 feet at a speed of about 20-100ft./min. The carbon steel metal strip has a resident time in the meltingpot of less than about 100 seconds. The coated carbon steel metal stripis passed through coating rollers and/or an air-knife to achieve anaverage coating thickness of about 3-77 microns. A heat createdintermetallic layer was formed that principally included copper andzinc. The tin and zinc layer was found to be porous and includedscattered small fingers of zinc penetrating through the tin to thesurface of the tin and zinc coating. Improved corrosion resistance wasobserved in the heat created intermetallic layer when the thickness ofthe plated copper later was over about 1 micron.

EXAMPLE FFF

A carbon steel metal strip is unwound from a roll of carbon steel metalstrip. The carbon steel metal strip has an average thickness of about762 microns. The carbon steel strip is plated with a copper layer ofabout 1-6 microns thick. A metal alloy having a composition of about91-95% tin and about 5-9% zinc is coated onto the carbon steel metalstrip. The carbon steel metal strip is passed through the melting pothaving a length of at least about 5 feet at a speed of about 20-100ft./min. The carbon steel metal strip has a resident time in the meltingpot of less than about 100 seconds. The coated carbon steel metal stripis passed through coating rollers and/or an air-knife to achieve anaverage coating thickness of about 3-77 microns. A heat createdintermetallic layer was formed that principally included copper andzinc. The tin layer was found to included tin and zinc. improvedcorrosion resistance was observed in the heat created intermetalliclayer when the thickness of the plated copper later was over about 1micron.

EXAMPLE GGG

This example is similar to Example EEE and FFF except that the basemetal strip is stainless steel instead of carbon steel. The phenomenaconcerning the composition of the heat created intermetallic layer andthe tin and zinc alloy coating as set forth in Example EEE and FFF alsoexisted in the coated stainless steel metal strip.

EXAMPLE HHH

A metal alloy is formed into a metal strip to be formed to various typesof materials, or into a solder or a welding wire for connecting two ormore metal materials together. One general composition of the metalstrip, solder or welding wire is 20-70% tin, 30-75% zinc, 0.0005-2%aluminum, 0.001-2% antimony, 0.0001-1% bismuth, 0-2% copper, 0-0.5%lead, 0.0001-0.1% titanium. Another and/or alternative formulation ofthe metal strip, solder or welding wire is 40-60% tin, 40-60% zinc,0.0005-0.75% aluminum, 0.001-1% antimony, 0.0001-0.2% bismuth, 0-0.01%arsenic, 0-0.01% cadmium, 0-0.01% chromium, 0.001-1% copper, 0-0.1%iron, 0-0.1% lead, 0-0.01% manganese, 0-0.2% nickel, 0-0.01% silver,0.0005-0.05% titanium. Still another and/or alternative formulation ofthe metal strip, solder or welding wire includes 30-70% tin; 30-70%zinc; 0.0001-0.5% aluminum; 0.001-2% antimony; 0-0.01% arsenic;0.0001-1% bismuth; 0-0.01% boron; 0-0.01% cadmium; 0-0.05% carbon;0-0.05% chromium; 0-2% copper; 0-0.1% iron; 0-0.5% lead; 0-0.01%magnesium; 0-0.01% manganese; 0-0.01% molybdenum; 0-1% nickel; 0-0.01%silicon; 0-0.01% silver; 0-0.01% sulfur; 0-0.01% tellurium; 0.0001-0.1%titanium; and 0-0.01% vanadium. Yet another and/or alternativeformulation of the metal strip, solder or welding wire is 40-60% tin;40-60% zinc; 0.0005-0.4% aluminum; 0.01-0.8% antimony; 0-0.005% arsenic;0.001-0.05% bismuth; 0-0.005% cadmium; 0.005-0.5% copper; 0-0.05% iron;0-0.1% lead; 0-0.05% nickel; 0-0.005% silver; and 0.0005-0.05% titanium.Still yet a further and/or alternative formulation of the metal strip,solder or welding wire is 48-52% tin; 48-52% zinc; 0.005-0.24% aluminum;0.05-0.64% antimony; 0-0.001% arsenic; 0.002-0.005% bismuth; 0-0.001%cadmium; 0.01-0.3% copper; 0-0.016% iron; 0-0.08% lead; 0-0.001% nickel;0-0.001% silver; 0.001-0.02% titanium. Another and/or alternativeformulation of the metal strip, solder or welding wire is 5-70% tin;30-95% zinc; 0-0.25% aluminum; 0-0.02% chromium; 0-1.5% copper; 0-0.01%iron; 0-0.01% lead; 0-0.01% manganese; and 0-0.18% titanium. When themetal alloy is used as a solder metal or electrode, the metal alloy istypically formed into a thin wire or thin strip by common knownprocesses. The thin wire or thin strip is typically rolled for laterprocessing or use. The metal alloy made for solder typically includesaluminum and/or titanium since these two metal additives positivelyaffect the surface tension of the metal alloy in the molten state sothat the molten metal alloy has the desired wetting characteristics. Thehigher the concentration of titanium and/or aluminum, the more thesolder will bead when applied to a workpiece. The addition of titaniumand/or aluminum to the metal alloy also causes the metal alloy to resistflowing at temperatures near the melting point of the metal alloy. Thisresistance imparts excellent soldering characteristics. The titaniumand/or aluminum are believed to cause oxide formation on the surface ofthe molten solder to form a dull greyish, earth tone colored solder. Thetitanium and aluminum are also believe to assist in forming anintermetallic layer with the tin and zinc in the metal alloy and theworkpiece before solidification of the solder to thereby form a strongbond with the workpiece. The solder typically includes little, if any,lead additions, and such, any lead in the solder is typically due toimpurities. The solder composition is particularly useful in solderingcarbon steel, stainless steel, copper, copper alloys, tin, tin alloys,zinc and zinc alloys. However, the solder can be used on other types ofmetals. If the solder is to be used to connect copper or copper alloys,copper is typically added to the metal alloy composition. The additionof copper reduces the reactivity of the solder with the copper or copperalloy materials. The solder may be used with a wide variety of fluxes.If the solder is to be used in ultrasonic welding, a flux is typicallynot used.

EXAMPLE III

The metal alloy is used for standing seam and press fit (mechanicaljoining such as, shown in U.S. Pat. No. 4,987,716) applications forroofing. In standing seam applications, the edges of the roofingmaterials are folded together and then soldered to form a water tightseal. The metal alloy inherently includes excellent solderingcharacteristics. When the metal alloy is heated, it has the necessarywetting properties to produce a tight water resistant seal. As a result,the metal alloy acts as both a corrosive resistive coating and asoldering agent for standing seam roofing systems. The metal alloycoated can be also welded with standard solders. Typical solders containabout 50% tin and about 50% lead. The metal alloy has the addedadvantage of being able to be soldered with low or no-lead solders. Themetal alloy coated roofing materials also can be used in mechanicallyjoined roofing systems due to the malleability of the metal alloy.Mechanically joined systems form water tight seals by folding adjacentroof material edges together and subsequently applying a compressiveforce to the seam in excess of about 1,000 psi. Under these highpressures, the metal alloy plastically deforms within the seam andproduces a water tight seal.

The invention has been described with reference to preferred andalternate embodiments. Modifications and alterations will becomeapparent to those skilled in the art upon reading and understanding thedetailed discussion of the invention provided herein. This invention isintended to include all such modifications and alterations insofar asthey come within the scope of the present invention.

1. A corrosion-resistant metal strip having a base metal strip coatedwith a corrosion-resistant metal alloy and a heat created intermetalliclayer between said metal alloy coating and said base metal strip, saidbase metal strip having a surface that includes copper prior to saidmetal alloy coating being coated on said base metal strip, said metalalloy coating including at least about 15 weight percent tin, an atleast an effective amount of zinc to form a multi-phase metal alloycoating after said metal ahoy coating cools on said base metal strip,said tin content plus said zinc content at least about 90 weightpercent, said heat created intermetallic layer including a majority ofcopper plus zinc and having a thickness of up to about 10 microns. 2.The corrosion-resistant metal strip as defined in claim 1, wherein saidbase metal strip includes a majority of copper.
 3. Thecorrosion-resistant metal strip as defined in claim 2, wherein said basemetal strip is a copper strip.
 4. The corrosion-resistant metal strip asdefined in claim 1, wherein said metal alloy coating has an averagethickness of less than about 30 microns.
 5. The corrosion-resistantmetal strip as defined in claim 3, wherein said metal alloy coating hasan average thickness of less than about 30 microns.
 6. Thecorrosion-resistant metal strip as defined in claim 1, wherein said basemetal strip has an average thickness of less than about 2540 microns,said base metal strip thickness being greater than said metal alloycoating thickness.
 7. The corrosion-resistant metal strip as defined inclaim 5, wherein said base metal strip has an average thickness of lessthan about 2540 microns, said base metal strip thickness being greaterthan said metal alloy coating thickness.
 8. The corrosion-resistantmetal strip as defined in claim 1, wherein said heat createdintermetallic layer includes at least about 75 weight percent copperplus zinc.
 9. The corrosion-resistant metal strip as defined in claim 7,wherein said heat created intermetallic layer includes at least about 75weight percent copper plus zinc.
 10. The corrosion-resistant metal stripas defined in claim 1, wherein said metal alloy coating includes atleast about 20 weight percent zinc.
 11. The corrosion-resistant metalstrip as defined in claim 9, wherein said metal alloy coating includesat least about 20 weight percent zinc.
 12. The corrosion-resistant metalstrip as defined in claim 10, wherein said metal alloy coating includesat least about 40 weight percent zinc.
 13. The corrosion-resistant metalstrip as defined in claim 1, wherein said metal alloy coating includesat least one metal additive to positively affect the chemical and/orphysical properties of said metal alloy coating; said metal additiveincluding a metal selected from the group consisting of aluminum,antimony, bismuth, chromium, copper, lead, magnesium, manganese,molybdenum, nickel, silicon, titanium, and mixtures thereof.
 14. Thecorrosion-resistant metal strip as defined in claim 9, wherein saidmetal alloy coating includes at least one metal additive to positivelyaffect the chemical and/or physical properties of said metal alloycoating; said metal additive including a metal selected from the groupconsisting of aluminum, antimony, bismuth, chromium, copper, lead,magnesium, manganese, molybdenum, nickel, silicon, titanium, andmixtures thereof.
 15. The corrosion-resistant metal strip as defined inclaim 11, wherein said metal alloy coating includes at least one metaladditive to positively affect the chemical and/or physical properties ofsaid metal alloy coating; said metal additive including a metal selectedfrom the group consisting of aluminum, antimony, bismuth, chromium,copper, lead, magnesium, manganese, molybdenum, nickel, silicon,titanium, and mixtures thereof.
 16. The corrosion-resistant metal stripas defined in claim 1, wherein said metal alloy comprises: Tin 15-90Zinc  9-85 Aluminum 0-2 Antimony 0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1Magnesium 0-2 Nickel 0-2 Titanium  0-1.


17. The corrosion-resistant metal strip as defined in claim 15, whereinsaid metal alloy comprises: Tin 15-90 Zinc  9-85 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2Titanium  0-1.


18. The corrosion-resistant metal strip as defined in claim 16, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium    0-0.1.


19. The corrosion-resistant metal strip as defined in claim 17, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium    0-0.1.


20. A corrosion-resistant metal strip having a base metal strip coatedwith a corrosion-resistant metal alloy and a heat created intermetalliclayer formed between said base metal strip and said metal alloy coating,said base metal strip formed of a majority of copper and having asurface which includes copper prior to being coated with said metalalloy coating, said metal alloy coating including about 9-80 weightpercent zinc and at least about 15 weight percent tin, said tin contentplus said zinc content of said metal alloy coating at least about 90weight percent, said base metal strip having an average thickness ofabout 381-2540 microns, said metal alloy coating having an averagethickness of about 2-1250 microns, said base metal strip having athickness greater than said metal alloy coating thickness, said heatcreated intermetallic layer including a majority of copper plus zinc andhaving an average thickness of about 0.3-20 microns.
 21. Thecorrosion-resistant metal strip as defined in claim 2, wherein said basemetal strip is a copper strip.
 22. The corrosion-resistant metal stripas defined in claim 20, wherein said metal alloy coating has an averagethickness of less than about 30 microns.
 23. The corrosion-resistantmetal strip as defined in claim 21, wherein said metal alloy coating hasan average thickness of less than about 30 microns.
 24. Thecorrosion-resistant metal strip as defined in claim 20, wherein saidheat created intermetallic layer includes at least about 75 weightpercent copper plus zinc.
 25. The corrosion-resistant metal strip asdefined in claim 23, wherein said heat created intermetallic layerincludes at least about 75 weight percent copper plus zinc.
 26. Thecorrosion-resistant metal strip as defined in claim 20, wherein saidmetal alloy coating includes at least about 20 weight percent zinc. 27.The corrosion-resistant metal strip as defined in claim 25, wherein saidmetal alloy coating includes at least about 20 weight percent zinc. 28.The corrosion-resistant metal strip as defined in claim 20, wherein saidmetal alloy coating includes at least one metal additive to positivelyaffect the chemical and/or physical properties of said metal alloycoating; said metal additive including a metal selected from the groupconsisting of aluminum, antimony, bismuth, chromium, copper, lead,magnesium, manganese, molybdenum, nickel, silicon, titanium, andmixtures thereof.
 29. The corrosion-resistant metal strip as defined inclaim 25, wherein said metal alloy coating includes at least one metaladditive to positively affect the chemical and/or physical properties ofsaid metal alloy coating; said metal additive including a metal selectedfrom the group consisting of aluminum, antimony, bismuth, chromium,copper, lead, magnesium, manganese, molybdenum, nickel, silicon,titanium, and mixtures thereof.
 30. The corrosion-resistant metal stripas defined in claim 27, wherein said metal alloy coating includes atleast one metal additive to positively affect the chemical and/orphysical properties of said metal alloy coating; said metal additiveincluding a metal selected from the group consisting of aluminum,antimony, bismuth, chromium, copper, lead, magnesium, manganese,molybdenum, nickel, silicon, titanium, and mixtures thereof.
 31. Thecorrosion-resistant metal strip as defined in claim 20, wherein saidmetal alloy comprises: Tin 15-90 Zinc  9-85 Aluminum 0-2 Antimony 0-2Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2 Titanium 0-1.


32. The corrosion-resistant metal strip as defined in claim 30, whereinsaid metal alloy comprises: Tin 15-90 Zinc  9-85 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2Titanium  0-1.


33. The corrosion-resistant metal strip as defined in claim 31, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium    0-0.1.


34. The corrosion-resistant metal strip as defined in claim 32, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium    0-0.1.


35. A corrosion-resistant metal strip having a copper base metal stripcoated with a multi-phase tin-zinc alloy coating and a heat createdintermetallic layer formed between said copper base metal strip and saidtin-zinc alloy coating, said metal alloy including at least about 15weight percent tin and at least an amount of zinc to form saidmulti-phase tin-zinc alloy, said tin content plus said zinc content atleast about 90 weight percent, said tin-zinc alloy including at leastone metal additive to positively affect the chemical and/or physicalproperties of said tin-zinc alloy, said metal additive including a metalselected from the group consisting of aluminum, antimony, bismuth,chromium, copper, lead, magnesium, manganese, molybdenum, nickel,silicon, titanium, and mixtures thereof, said copper base metal striphaving an average thickness of about 381-1270 microns, said tin-zinccoating having an average thickness of about 2-77 microns, said heatcreated intermetallic layer including a majority of copper plus zinc andhaving an average thickness of about 0.3-20 microns, said thickness ofsaid tin-zinc alloy coating being greater than said thickness of saidheat created intermetallic layer.
 36. The corrosion-resistant metalstrip as defined in claim 35, wherein said metal alloy coating has anaverage thickness of less than about 30 microns.
 37. Thecorrosion-resistant metal strip as defined in claim 35, wherein saidheat created intermetallic layer includes at least about 75 weightpercent copper plus zinc.
 38. The corrosion-resistant metal strip asdefined in claim 36, wherein said heat created intermetallic layerincludes at least about 75 weight percent copper plus zinc.
 39. Thecorrosion-resistant metal strip as defined in claim 35, wherein saidmetal alloy coating includes at least about 20 weight percent zinc. 40.The corrosion-resistant metal strip as defined in claim 38, wherein saidmetal alloy coating includes at least about 20 weight percent zinc. 41.The corrosion-resistant metal strip as defined in claim 35, wherein saidmetal alloy comprises: Tin 15-90 Zinc  9-85 Aluminum 0-2 Antimony 0-2Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2 Titanium 0-1.


42. The corrosion-resistant metal strip as defined in claim 40, whereinsaid metal alloy comprises: Tin 15-90 Zinc  9-85 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Copper 0-2 Iron 0-1 Magnesium 0-2 Nickel 0-2Titanium  0-1.


43. The corrosion-resistant metal strip as defined in claim 41, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium    0-0.1.


44. The corrosion-resistant metal strip as defined in claim 42, whereinsaid metal alloy comprises: Tin 45-55 Zinc 45-55 Aluminum 0-2 Antimony0-2 Bismuth   0-1.7 Boron   0-0.01 Cadmium   0-0.1 Carbon   0-0.5Chromium   0-0.5 Copper 0-2 Iron 0-1 Lead   0-0.5 Magnesium   0-0.4Manganese   0-0.1 Molybdenum   0-0.1 Nickel 0-2 Silicon   0-0.5 Titanium0-1 Vanadium    0-0.1.